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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a national phase application based on PCT/EP2009/054350, filed Apr. 10, 2009 the content of which is incorporated herein by reference, which claims the priority of PCT/IT/2008/000541, filed Aug. 8, 2008.
FIELD OF THE INVENTION
The present invention relates to the filtering of exhaust gas emissions. Particularly, the present invention relates to the regeneration of filters of particulate emissions produced by combustion processes, like those occurring in a diesel engine.
BACKGROUND OF THE INVENTION
With the term “exhaust gas” it is intended a flue gas that is produced as a result of the combustion of fuels, such gasoline/petrol, diesel, fuel oil or coal. The ever increasing diffusion of power plants, industrial process plants, and motor vehicles in the world, has urgently led to the study of possible solutions for reducing the harmful effects of the exhaust gases on the environment and on the man.
Indeed, although the largest part of most exhaust gases is relatively harmless nitrogen, water vapor (exception made for pure-carbon fuels), and carbon dioxide (with the exception of hydrogen as fuel), a relatively small part thereof is formed by undesirable toxic substances, such as carbon monoxide, hydrocarbons, nitrogen oxides, partly unburnt fuel, and particulate matter. Generally speaking, with the term “particulate matter” (briefly referred to as “PM”) it is intended solid or liquid particles suspended in a gas. In an exhaust gas, such as the exhaust gas produced by a diesel engine, the main fraction of PM is composed of very small particles, mainly consisting of impure carbon particles (in jargon, also referred to as “soot”). Because of their small size, said particles, when inhaled, may easily penetrate deep into the lungs. The rough surfaces of these particles make it easy for them to bind with other toxins in the environment, thus increasing the hazards of particle inhalation. The discharge amount of PM becomes large in a diesel engine using a gas oil as a fuel or a direct-injection type gasoline engine recently coming into wide use.
A solution for removing (or at least reducing) the PM emissions of an exhaust gas produced by fuel combustion, e.g., in a vehicle engine, provides for the use of a particulate filter. Making reference to the exhaust gas produced by a diesel engine, a particulate filter—in this case, referred to as Diesel Particulate Filter (DPF)—is a device arranged in an exhaust gas emission path of the diesel engine for receiving the exhaust gas and retain the PM included thereinto.
A conventional DPF may consist of a cylindrical body made of porous material, such as silicon carbide (SiC), with a first base (upstream side) receiving the flow of the exhaust gas produced by the engine. Such DPF has a honeycomb structure, with a plurality of exhaust gas flowing channels extending in parallel to the longitudinal direction of the cylindrical body, from the upstream side body to a downstream side, corresponding to a second base of the cylindrical opposite to the first one. These channels are alternatively plugged at either the upstream side or the downstream side to form a checker pattern. The exhaust gas (including PM) hits the first surface, and is forced to flow through the channels of the DPF that are not plugged at the upstream side. Thanks to the porosity properties of the SiC, the PM included in the exhaust gas is blocked by the walls of said channels, and remain confined in the DPF, while the rest of the exhaust gas (essentially free of PM) crosses the walls, passes into the adjacent channels and exits from the DPF, for being outputted outside the vehicle through exhaust pipes.
While disposable DPFs exist, the majority of the current DPFs are designed to be subjected to cleaning operations for removing from the DPF the PM accumulated with the use. Particularly, said cleaning operations, also known as filter regeneration operations, may provide for burning off the accumulated PM, providing heat to the accumulated PM in such a way that the latter reaches its burning temperature—which, for a PM made of carbon particles, is around 600-650° C.
According to a first method known in the art, the filter regeneration is performed in a “passive” way, with the DPF that is brought to the burning temperature of the PM by exploiting the heat of the exhaust gas itself Since however it is very difficult to reach the burning temperature of 600-650° C. by simply using the heat of the exhaust gas only, a fuel additive is mixed together with the fuel, which lowers the burning temperature of the PM of about 300° C. According to the latter method, if the temperature of the exhaust gas reaches 300-350° C. and is maintained for a certain time, the PM collected in the DPF burns for spontaneous combustion, emptying the channels thereof However, even in presence of the fuel additive, bringing the temperature of the exhaust gas to said temperature may be quite difficult, especially for those vehicles equipped with small engines, that frequently run in urban areas at a low speed, lift trucks, operative vehicles that work for long period at the idling condition, and the like. This involves an undesired build-up of PM within the DPF, which even after few hours of operations may occlude the channels of the DPF, with a consequent power off of the vehicle. In view of these reasons, the passive filter regeneration is quite inefficient.
According to a second method known in the art, the filter regeneration is performed in an “active” way, with additional heat that is supplied to the DPF by an external source, to reach the burning temperature of the PM in an easiest way. For example, the DPF may be provided with proper heating devices, that are periodically activated to heat the exhaust gas before it enters into the channels of the DPF. Also according to this solution, the fuel can be mixed with proper fuel additives, for lowering the burning temperature of the PM and facilitating the filter regeneration. For example, the heating devices may be implemented with a spiral-shaped resistance, or with ceramic or metal glow plugs positioned in the proximity of the upstream side of the DPF. Said heating devices are controlled by a suitable control unit in such a way as to heat the exhaust gas at predetermined times for favoring the trigger of the burning of the PM included in the DPF.
The European Patent application EP 990777A1 discloses a regeneration system for an exhaust gas cleaning device disposed in an exhaust emission path of an internal combustion engine. The regeneration system comprises an exhaust gas cleaning honeycomb filter and a heating means for the filter. The filter is a checkered SiC honeycomb filter having a given cell structure, and the heating means is a heater or a glow plug when using a fuel containing fuel additive.
The European Patent application EP 1582714A1 discloses a system and a method for regenerating particulate filters. Particularly, estimated values of an amount of accumulated particulate matter on a particulate filter are obtained before initiation of a forceful regeneration operation of the particulate filter. A maximum operating time period of the regeneration operation is set based on the estimated values of the amount of accumulated particulate matter. The particulate filter is regenerated in the regeneration operation by performing post fuel injection in the diesel engine during each exhaust stroke of the diesel engine to supply fuel to the particulate filter and thereby to remove particulate matter from the particulate filter through use of combustion heat of the supplied fuel upon combustion of the supplied fuel.
The French patent 2771449B1 discloses a further method and device for the regeneration of a particulate filter. Particularly, heat is provided to local portions of the particulate filter when the counter pressure upstream of the filter exceeds a predetermined threshold value. Said predetermined threshold value is chosen to be lower than the counter pressure for which the particulate burns by self combustion at the average temperature of the exhaust gas inside the particulate filter. The predetermined threshold value depends on the load of the engine and its Revolutions-Per-Minute (RPM). In particular, heat is provided to the particulate filter when the RPM of the engine are low, and particularly when they are lower than or equal to 50% of the maximum RPM of the engine.
SUMMARY OF THE INVENTION
The Applicant has observed that known solutions for performing the particulate filter regeneration are often not efficient, expensive, energy consuming for the vehicle, and not always useful. Indeed, with many solutions already known in the art, the burning of the PM retained by the filter may be triggered when it is not really necessary, or even it may not succeed.
As a matter of fact, the solutions for performing the particulate filter regeneration often need a deep interaction with a number of vehicle's components (e.g. the engine, for deriving a number of parameters related to the operation of the engine itself), so that the addition of a particulate filter system, including a regeneration system of the filter, particularly in a vehicle which was not originally equipped with the same (i.e. a retrofit), is hardly accomplishable due to the inherent complexity of such solutions.
The Applicant has observed that it would be desirable to perform the activation of the regeneration operations only when necessary, for improving the efficiency of the regeneration process without wasting the vehicle energy budget.
The Applicant has also observed that the conditions for the activation of the particulate filter regeneration should be as simple as possible, particularly in order to provide the possibility to a vehicle to be equipped with a particulate filter system as a retrofit system (thereby improving its exhaustion emission category) without a substantial amount of needed space in the vehicle and/or installation time.
The Applicant has also observed that a vehicle may behave in a very different manner from other vehicles in terms of produced PM per time unit, in dependence of many factors, such as, e.g., the type of engine, the conditions of use, the traveled path, etc.
Additionally, even considering the same vehicle, its behavior typically changes during its life, with an impact on the produced PM. The Applicant has thus observed that a filter regeneration system should contemplate the possibility of tracking, as far as the activation of the regeneration operations is concerned, the changes in the behavior of the vehicle.
The Applicant has found that different operating conditions of a vehicle can be detected based on few sensed data relating exhaust emissions of its engine. The Applicant has also found that it is possible to set, and possibly adjust, one or more thresholds in order to activate the particulate filter regeneration operations based on the detected operating conditions of the vehicle, preferably based on a statistical analysis of the sensed data, so as to adapt the activation of the regeneration operations to the vehicle type and/or actual use, with a positive effect on the resulting efficiency of the filter regenerations.
In this regard, the Applicant has observed that the pressure of the exhaust emissions sensed at the input of the particulate filter is a very useful parameter for assessing when the activation of the particulate filter regeneration operations should be performed.
However, the Applicant has also observed that the pressure of the exhaust emissions sensed at the input of the particulate filter is actually a largely fluctuant parameter, particularly when a vehicle is driven in urban areas, so that a simple activation of the filter regeneration triggered by a generically “high” value of instantaneous pressure at the input of the filter (as suggested, for example, in the above mentioned document FR 2771449) does not lead to an effective solution of the problem of when the activation of the filter regeneration should be performed. Indeed, the Applicant has found that such simple solution does not work, because a threshold for the activation is hardly settable.
In particular, after a number of tests it has been found that in many cases the regeneration was activated when not needed, due to the fact that a high pressure of the exhaust gases was just obtained because the engine was working at high RPM, and not because the filter was full of accumulated soot. In other cases, the filter actually needed regeneration, but a high instantaneous pressure due to a working of the engine at high RPM leaded to an excessive heat removal in the filter, and finally to a failure of the soot combustion.
Differently, it has been found that by performing an average of the pressure values of the exhaust emissions sensed during a certain time interval (e.g. 30 minutes) at the input of the particulate filter, an indication of the actual load of PM in the particulate filter could be derived: in particular, it has been found that a low average pressure may indicate that it is still not necessary to start the particulate filter regeneration operations, since the PM included in the particulate filter is too low. In other words, it has been found that an averaging of the pressure values sensed during a certain time interval (e.g. 30 minutes) may be used as a quite precise indication of whether the particulate filter needs regeneration. In spite of the fact that the instantaneous pressure value at a certain time can largely fluctuate, the average pressure is a slow varying parameter, which is indicative of the degree of soot accumulation in the filter.
With regards to the instantaneous pressure, i.e. the pressure value which is sensed (at the input of the particulate filter) at a certain time instant, the Applicant has surprisingly found that low values of such pressure do often fail to activate the filter regeneration.
On the other hand, still surprisingly, it was found that high values of instantaneous pressure were occasionally associated with the desired activation of the filter regeneration.
Subsequent statistical considerations, made on series of pressure values collected in a substantial number of time intervals, leaded to the conclusion that “exceptionally high” values of the instantaneous pressure may be used as “trigger” of the activation of the regeneration operations once the average pressure value indicates that the particulate filter is ready for being regenerated.
This result is surprising, because, indeed, the value of the instantaneous pressure is related to the flow of the exhaust gas at the input of the particulate filter. Since the higher the flow rate of the flow, the higher the heat removal rate from the particulate filter, one would normally anticipate that the heating device used for the activation of the regeneration should be turned-on when the flow is as small as possible. To the contrary, as already anticipated, the Applicant has observed that after the occurrence of high peaks of instantaneous pressure there is a very high probability that the instantaneous pressure (and correspondingly the flow of exhaust gas at the input of the particulate filter) falls. It is believed that such fall is due to the fact that, with all probability, the engine RPM decreases to a substantially lower regime. Thus, substantially every time a high peak of instantaneous pressure is detected, the flow of exhaust gas is likely to subsequently decrease to a condition which is favorable for the combustion of the PM.
It has particularly been found that the decrease of the engine RPM to a lower regime (and consequently of the instantaneous pressure at the input of the filter) is likely to occur in a time window, which is compatible with the propagation of the soot combustion in the whole filter, after the turning-on of the heating device(s) activating the regeneration.
The Applicant has thus found that the problem of activating the regeneration of the particulate filter can be solved by treating the pressure sensed at the input of the particulate filter in a separate manner, i.e. as a slowly varying parameter obtained by averaging on a number of collected pressure data for a correlation with the quantity of soot in the particulate filter, and as a largely fluctuating instantaneous parameter to be used as a trigger for the activation of the regeneration once the average pressure value indicates that the quantity of soot is high enough to be removed. In particular, such trigger corresponds to a high improbable value of the instantaneous pressure, i.e. an “exceptionally high” value. Typically, such high improbable value corresponds to a very high engine RPM regime.
An aspect of the present invention relates to a method for inducing the regeneration of a particulate filter associated with an exhaust gas emitting engine while being operated in a vehicle in variable driving conditions.
Another aspect of the present invention relates to a regeneration system for inducing the regeneration of a particulate filter associated with an exhaust gas emitting engine that operates in a vehicle in variable driving conditions.
A further aspect of the present invention relates to a filter system for filtering particulate matter present in exhaust emissions of an engine of a vehicle.
A still further aspect of the present invention relates to a vehicle including an exhaust gas emitting engine and a particulate filter system.
The invention, in one or more of the above aspects, comprises one or more of the following preferred features.
At least one heating device is disposed substantially in punctual contact with the filter at its gas entrance so as to cause a local heating thereof. The at least one heating device is turned on when the activation of the regeneration starts.
At least the pressure of the exhaust emissions at the input of the particulate filter is sensed. The turning on of the at least one heating device is conditioned to a comparison of the sensed data with at least one respective threshold.
Particularly, an average pressure is obtained from a number of sensed pressure values. The average pressure should be higher than a respective minimum threshold, which is related to the load of PM in the particulate filter.
Moreover, preferably, when the average pressure is higher than its respective minimum threshold, the at least one heating device is activated when the instantaneous pressure is higher than a further respective minimum threshold.
The minimum threshold for the instantaneous pressure is preferably set to a value sufficiently high to be reached by the instantaneous pressure only during the high peaks thereof
More particularly, the minimum threshold for the instantaneous pressure is set to a high improbable pressure value, capable of being reached in presence of high peaks of instantaneous pressure only.
It is believed that, to the purposes of the present invention, the engine RPM value can be used, in combination with the average pressure as described above, instead of the instantaneous pressure as a trigger for the activation of the filter regeneration. However, the need to work with the average pressure over a time window implies the detection of the instantaneous pressure. Hence, the instantaneous pressure is a parameter readily available as a matter of course. Moreover, working with pressure values makes easy to install the particulate filter regeneration system in a vehicle with no needed interface with its engine.
The PM combustion process triggered by locally heating the particulate filter with the heating device is not instantaneous, but requires an amount of time to propagate in the whole extent of the particulate filter. For this purpose, the at least one heating device is turned on for a time period sufficiently long for the instantaneous pressure to get from such value higher than the minimum threshold to a significantly lower value.
The value of said pressure threshold could be adjusted based on an operating condition of the vehicle. The operating condition can be detected based on the received sensed data.
With the proposed method, the efficiency of the regeneration process of the particulate filter can be substantially improved, both in terms of power consumption and reliability.
In particular, it has been found that the proposed solution allows a better tuning of the activation of the regeneration operations, such that the heating device is activated only when the conditions for successful filter regeneration are favorable.
Thus, the occurrence of unnecessary activations of the heating device is reduced, so as to avoid excessive waste of electrical power.
Moreover, the performances of the regeneration can be dynamically and autonomously improved based on the actual vehicle condition and the actual driving condition. In particular, the operations performed by the proposed filter regeneration method and/or system are based on threshold values that can dynamically evolve based on the actual vehicle conditions and the actual driving condition.
According to a preferred embodiment of the present invention, a collection of last received data is kept (e.g. it is stored in a memory of a control unit of the regeneration system).
Particularly, according to an embodiment of the present invention, a collection of the more recent received data of the exhaust emissions instantaneous pressure (sensed at the input of the particulate filter) is kept.
Moreover, the adjustment of the pressure threshold may be performed by determining said high improbable value of the instantaneous pressure based on a statistical analysis of the data in said collection.
Particularly, said statistical analysis may be performed by obtaining a statistical distribution of the data in the collection. The value of said high improbable value can be determined based on a predetermined percentile of said statistical distribution.
The setting of the instantaneous pressure threshold can thus advantageously be performed in a simple way, without excessive calculation complexity.
Preferably, said predetermined percentile is at least higher than a 90th percentile of the statistical distribution. In such way the peaks of the instantaneous pressure reached during use of the vehicle in the period corresponding to the collected data can be easily identified.
According to an embodiment of the present invention, the at least one heating device is kept activated for a time period sufficiently long for the instantaneous pressure to get from such value higher than the high improbable value to about one third of said high improbable value.
In a further embodiment, the adjustment of the pressure threshold can be performed by assessing a result of a filter regeneration based on the received data after the occurrence of a previous filter regeneration. The value of said pressure threshold can be adjusted based on the assessed result. A fine tuning of the regeneration process can thus be performed.
Preferably, said assessing the result of a filter regeneration based on the data of the exhaust emissions average pressure includes assessing if the average pressure of the exhaust emissions after a previous filter regeneration is lower than a further predetermined threshold value.
According to a further embodiment of the present invention, a number of successful regenerations and a number of unsuccessful regenerations could be quantified based on assessed results of consecutive filter regenerations.
For example, the threshold value on the average pressure can be increased by a first amount if said number of unsuccessful regenerations has reached a first predetermined limit or can be decreased by a second amount if said number of successful regenerations has reached a second predetermined limit.
This adjustment of the average pressure threshold provides another fine tuning of the activation of the regeneration operations.
Preferably, the values of said first and second amounts depend on the difference between the value of the exhaust emissions average pressure after the filter regeneration and the threshold value previously set.
The Applicant has observed that the temperature of the exhaust emissions sensed at the output of the particulate filter is another very useful parameter for assessing when activating the particulate filter regeneration operations in an efficient way.
Particularly, activating the heating device when the temperature of the exhaust gas is too low may obstacle the triggering of the burning of the PM. This is a great drawback, since the activation of the heating device consumes a non-negligible electric power, which in this case is entirely wasted. Wasting the already limited vehicle battery power is highly undesirable.
For this purpose, a preferred embodiment of the present invention provides for conditioning the activation of the heating device based on a comparison on received data relating to the instantaneous temperature sensed at the output of the particulate filter with a minimum and a maximum threshold. This is performed in order to asses—if the temperature of the particulate filter is sufficiently high for allowing the propagation of the PM combustion through the whole particulate filter, and/or if it is lower than a maximum value, above which the activation of the heating device would be unnecessary, since the PM would burn for spontaneous combustion.
According to an embodiment of the present invention, a collection of last received data regarding the instantaneous temperature of the exhaust emissions of said vehicle engine is kept (e.g. it is stored in a memory of a control unit of the regeneration system).
The setting of the value of at least one among the lower instantaneous temperature threshold and the higher instantaneous temperature threshold can be performed based on a statistical analysis of the data in said collection.
Preferably, said statistical analysis is performed by obtaining a statistical distribution of the data in the collection.
In an embodiment of the invention, the value of at least one among the lower instantaneous temperature threshold and the higher instantaneous temperature threshold are determined based on at least one predetermined percentile of said statistical distribution.
The setting of the lower and/or the higher instantaneous temperature threshold(s) can thus advantageously be performed in a simple way, without excessive calculation complexity.
In particular, the value of the lower instantaneous temperature threshold can be set on the basis of a first predetermined percentile of said statistical distribution.
Furthermore, the value of the higher instantaneous temperature threshold can be set on the basis of a second predetermined percentile of said statistical distribution.
According to an embodiment of the present invention, said first predetermined percentile is at least higher than a 70th percentile of a first statistical distribution of received data related to an operating condition of the vehicle being unfavorable for the regeneration of the particulate filter.
Preferably, said first predetermined percentile is at least higher than a 95th percentile of the statistical distribution.
According to an embodiment of the present invention, said second predetermined percentile is at least lower than a 45th percentile of a second statistical distribution of received data related to an operating condition of the vehicle being favorable for the regeneration of the particulate filter.
Preferably, said second predetermined percentile is at least lower than a 30th percentile.
According to an embodiment of the present invention, the value of the lower instantaneous temperature threshold is not lower than a minimum temperature required for performing the regeneration of the particulate filter.
According to a further embodiment of the present invention, the value of the higher instantaneous temperature threshold is not higher than a maximum temperature for which the regeneration of the particulate filter is self-performed without the need of the activation of the heating device.
The above mentioned minimum and maximum temperatures can be set as default threshold parameters for the instantaneous temperature at the installation of the particulate filter, to be then adjusted according to preferred embodiments of the invention.
Furthermore, the Applicant has observed that the instantaneous temperature sensed at the output of the particulate filter is also a useful parameter for assessing when deactivating the heating device, avoiding waste of the vehicle battery. Particularly, once the burning of the PM has been sufficiently propagated across the particulate filter, the heating device may be deactivated, since—at this time—the burning of the PM is self-sustained, and is capable of continuing without the need of the additional heat provided by the heating device. The Applicant has found that said condition of self-sustained burning may be detected from the occurring of a relatively high increasing rate of the instantaneous temperature sensed at the output of the particulate filter.
In view of the above, a preferred embodiment of the present invention provides for turning off the heating device at a time corresponding to such a relatively high increasing rate of the instantaneous temperature sensed at the output of the particulate filter due to the combustion of the PM.
In order to perform the above mentioned activities, the regeneration system typically includes a control unit adapted to turn on for a time period the at least one heating device substantially in punctual contact with the particulate filter at its gas entrance if the average pressure of the exhaust gas at the gas entrance of the particulate filter is greater than a predetermined value, and if the instantaneous pressure of the exhaust gas at the gas entrance of the particulate filter is at a high improbable value.
Furthermore, the system includes a pressure sensor for sensing the pressure of the exhaust gas at the input of the particulate filter.
In this way, the control unit may receive sensed data relating to the sensed pressure, keep a collection of last received data, and determine and/or adjust said predetermined value and/or said high improbable value based on a statistical analysis of the data in the collection.
According to an embodiment of the present invention, the system further includes a temperature sensor for sensing the temperature of the exhaust gas at the output of the particulate filter.
In this way, the control unit may receive sensed data relating to the sensed temperature, keep a collection of last received data, and determine and/or adjust higher and/or lower instantaneous temperature thresholds to be used for conditioning the activation of the heating device.
According to an embodiment of the present invention, the particulate filter is a SiC filter. The filter may have a honeycomb structure.
According to an embodiment of the present invention, the at least one heating device comprises a number of glow plugs.
In view of the above, the filter regeneration system of the present invention needs very few additional hardware resources to be installed on the vehicle.
Indeed, only the addition of a filter regeneration apparatus including a temperature sensor after the particulate filter, glow plugs directly contacting the particulate filter (and preferably, its input base), and an electronic control unit can be advantageously provided for the installation of the particulate filter.
Consequently, the proposed filter regeneration system may be advantageously installed in whichever vehicle type, without having to drastically modify the fabrication process of the vehicle itself Thus, the proposed filter regeneration system is particularly adapted to be sold as an aftermarket product, i.e., as an accessory to be installed as a retrofit in an already operating vehicle.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features and advantages of the present invention will be best understood by reading the following detailed description of some embodiments thereof, given purely by way of a non-limitative example, to be read in conjunction with the accompanying drawings, wherein:
FIG. 1 is a possible application of a filter regeneration control system according to an embodiment of the present invention;
FIG. 2 illustrates a sectional view of a vehicle exhaust device included in the system of FIG. 1 ;
FIG. 3 illustrates an exemplary structure of a control unit included in the system of FIG. 1 ;
FIG. 4A depicts a flow chart illustrating the main operations performed by the filter regeneration control system of FIG. 1 ;
FIG. 4B depicts a diagram showing an exemplary evolution in time of the instantaneous pressure during the vehicle operation;
FIG. 4C depicts two diagrams showing exemplary evolutions in time of the instantaneous pressure and of the instantaneous temperature during some operations performed by the filter regeneration control system in the flow chart of FIG. 4A ;
FIG. 5A depicts a flow chart illustrating the operations performed by the control unit of FIG. 1 for determining instantaneous pressure threshold values to be used for the operations performed by the filter regeneration control system in the flow chart of FIG. 4C ;
FIG. 5B depicts an exemplary statistical distribution of a instantaneous pressure log;
FIG. 6 depicts a flow chart illustrating the operations performed by the control unit of FIG. 1 for determining average pressure threshold values to be used for the operations performed by the filter regeneration control system in the flow chart of FIG. 4C ;
FIG. 7A illustrates experimental results obtained through an exemplary temperature test campaign;
FIG. 7B depicts a flow chart illustrating the operations performed by the control unit of FIG. 1 for determining temperature threshold values to be used for the operations performed by the filter regeneration control system in the flow chart of FIG. 4C , and
FIG. 7C depicts exemplary statistical distributions of instantaneous temperatures used for performing the operations of the flow chart of FIG. 5B .
DETAILED DESCRIPTION
With reference to the drawings, FIG. 1 illustrates in terms of schematic blocks a possible application of a filter regeneration control system according to an embodiment of the present invention.
More particularly, in the scenario illustrated in FIG. 1 , a vehicle 100 , for example a car or a van, is equipped with an engine 105 , for example of the diesel type, which generates kinetic energy for moving the vehicle 100 . The vehicle 100 further includes a fuel tank 110 adapted to store fuel, such as gas oil; the fuel stored in the fuel tank 110 is supplied to the engine 105 through a fuel pipe 115 , for being combusted in the engine 105 in order to generate the kinetic energy that causes the vehicle 100 to move.
The combustion process of the fuel occurring in the engine 105 produces exhaust gas, which is evacuated to the outside of the vehicle 100 through a vehicle exhaust device 120 ; particularly, the vehicle exhaust device 120 comprises a Diesel Particulate Filter (DPF) 125 provided with an exhaust pipe. The vehicle exhaust device 120 , and in particular the DPF 125 attenuate the acoustic emissions generated by the engine 105 of the vehicle 100 ; if desired, the acoustic emissions generated by the vehicle 100 may be further reduced by providing the vehicle with a muffler, arranged to receive exhaust gas from the DPF 125 . The vehicle exhaust device 120 further includes a heating device 127 contacting an input surface of the DPF 125 for locally heating portions of said input surface of the DPF 125 , in order to promote the local triggering of the burning of PM in said portions of the DPF, as will be described in greater detail in the following of the present description.
As already discussed in the introduction of the present description, the purpose of the DPF 125 is to retain the PM included in the exhaust gas generated by the engine 105 , in such a way that the (filtered) exhaust gas being outputted into the air is less harmful for the human health and for the environment in general.
A more detailed description of the vehicle exhaust device 120 according to an embodiment of the present invention will be now provided with reference to FIG. 2 . Particularly, FIG. 2 illustrates a sectional view of the vehicle exhaust device 120 taken along a direction II-II parallel to a longitudinal axis LA of the vehicle exhaust device 120 of FIG. 1 .
The DPF 125 comprises a generically cylindrical body made of porous material, such as silicon carbide (SiC), with a first base BI (also referred to as “input base”) receiving the flow of the exhaust gas—denoted in the figure with the reference FLin—produced by the engine 105 . The DPF 125 has a honeycomb structure, with a plurality of exhaust gas flowing channels FLCH extending in parallel to the longitudinal direction of the cylindrical body from the input base BI to a second base BO (“output base”) of the cylindrical body opposite to the input one. The exhaust gas flowing channels FLCH are alternatively plugged at either the input base BI or the output base BO by means of respective closure elements PE to form a checker pattern.
Without entering into details known to those skilled in the art, a SiC DPF having a honeycomb structure can be obtained starting from a SiC paste in the following way. Briefly, a number of DPF portions having the length of the desired final DPF are firstly formed by means of extrusion operations performed on the SiC paste; during this step, also the various exhaust gas flowing channels FLCH are generated through extrusion. At this point, one end of each exhaust gas flowing channel FLCH of each DPF portion is plugged. Finally, the various DPF portions are cemented to each other, in order to form the DPF 125 . It has to be appreciated that a DPF obtained with such method presents on both its bases cementing lines (not illustrated in the figure) between each pair of adjacent DPF portions that has been cemented to form the final DPF. For example, in case the DPF 125 has been obtained starting from four DPF portions, the bases of the final DPF will present four different sections, delimited by respective cementing lines. It has to be appreciated that the presence of more than one portion cemented to each other allow to obtain a more stable and resistant structure with respect to the case of a monolithic DPF.
The DPF 125 is inserted (in jargon, “canned”) into a protective container 205 , for example a metallic (e.g., made of stainless steel) cylinder. The protective container 205 has an input aperture CBI corresponding to the input base BI of the DPF 125 and an output aperture CBO corresponding to the output base BO of the DPF 125 . An input lid structure 210 is connected to the protective container 205 for covering the input aperture CBI, while an output lid structure 215 is connected to the protective container 205 for covering the output aperture CBO. The input lid structure 210 is provided with a pipe union member 220 adapted to receive the flow FLin of the exhaust gas produced by the engine 105 .
In operation, the vehicle exhaust device 120 receives exhaust gas from the engine 105 . The flow FLin of the exhaust gas is collected by the pipe union member 220 of the input lid structure 210 , and is conveyed toward the input base BI of the DPF 125 . In this way, the exhaust gas is forced to flow through those exhaust gas flowing channels FLCH that are not plugged at the input base BI, until reaching the plug elements PE. As a consequence, since said exhaust gas flowing channels FLCH are blocked by the plug elements PE, the exhaust gas is forced to cross the later walls, so as to reach the adjacent exhaust gas flowing channels FLCH—which are not plugged at the output base BO—and exit from the DPF 125 . Particularly, thanks to the porosity properties of the SiC forming the walls of the gas flowing channels FLCH, the PM included in the exhaust gas remains confined in the DPF 125 , while the (filtered) exhaust gas crosses said walls and flows through the channels FLCH that are not plugged at the output base BO. The exhaust gas exiting the output base BO forms an output flow of (filtered) exhaust gas—denoted in the figure with the reference Flout—which is evacuated, through a pipe union member 225 on the output lid structure 215 , to the output of the vehicle 100 .
The heating device 127 for heating the flow FLin of the exhaust gas generated by the engine 105 comprises at least one, preferably a plurality of glow plugs GLP, for example including a glow plug GLP for each section of the input base BI. Each glow plug GLP has an end that is provided with a heating element HE capable of reaching temperatures of the order of 900-1000° C. when electrified due to electrical resistance.
According to an embodiment of the present invention, the glow plugs GLP forming the heating device 127 are positioned in the input lid structure 210 in such a way that the heating elements HE are in physical contact with, i.e., in punctual abutment to, the (corresponding section of the) input base BI of the DPF 125 . Particularly, the input lid structure 210 is provided with threaded bushings 230 adapted to accommodate the glow plugs GLP with an angle σ with respect to the longitudinal axis LA of the DPF 125 , so as not to obstacle the flow FLin of exhaust gas. In order to improve the efficiency of the filter regeneration process obtainable with the proposed structure, the glow plugs GLP are screwed in the respective threaded bushings 230 to an extent such that the heating element HE of each glow plug GLP results in contact with the surface of the input base BI in any operative condition.
In order to be activated for promoting the triggering of the burning of PM in the DPF 125 , the glow plugs GLP need to be properly supplied with electrical power. For this purpose, the vehicle 100 further comprises a supply block 135 including relays supplied in turn by a vehicle battery 140 , as illustrated in FIG. 1 .
The vehicle exhaust device 120 is provided with sensors adapted to monitor some physical quantities related to the condition of the DPF 125 and the exhaust gas flowing therethrough.
Particularly, a pressure sensor PRS is positioned within the input lid structure 210 , in the proximity of the input base BI of the DPF 125 . As will be described in greater detail in the following of the present description, the pressure sensor PRS allows to obtain useful information regarding the PM accumulated in the DPF 125 , based on the measurement of the “counter-pressure” generated by the flow FLin of exhaust gas when passing through the DPF 125 .
Moreover, a temperature sensor TES, such as a thermocouple or a thermistor, is positioned within the output lid structure 215 , in the proximity of the output base BO of the DPF 125 . As will be described in greater detail in the following of the present description, the temperature sensor TES allows to obtain useful information regarding the temperature of the DPF 125 based on the temperature of the flow FLout outputted by the DPF 125 .
Referring back to FIG. 1 , the vehicle 100 further includes an additive tank 145 , which is used to store a fuel additive adapted to be mixed with the fuel in such a way as to alter some of its chemical/physical attributes; particularly, as already explained in the introduction of the description, the fuel additive is mixed with the fuel for lowering the burning temperature of the PM included in the gas exhaust generated by the combustion of the fuel. For this purpose, the fuel additive is injected into the fuel pipe 115 by means of a clutch 150 connected to a pipe coming from the additive tank 145 .
The operations performed by the filter regeneration control system according to an embodiment of the present invention are managed by an electronic control unit, globally denoted in FIG. 1 with the reference 160 . The control unit 160 is coupled with the vehicle exhaust device 120 , and in particular with the pressure sensor PRS and the temperature sensor TES. As will be described in the following of the present description, the control unit 160 processes the information received from the sensors PRS, TES, and as a result of said processing determines when the heating device 127 has to be turned on for favoring the triggering of the filter regeneration process in an efficient way, and accordingly drives the supply block 135 for activating the glow plugs GLP.
In FIG. 3 , an exemplary structure of the control unit 160 is schematically shown in terms of functional blocks. Several functional units are connected in parallel to a data communication bus 305 . In particular, a processing unit 310 , typically comprising a microprocessor or a microcontroller or any other suitable data processing unit, controls the operation of control unit 160 ; a working memory 315 , for example volatile registers, is directly exploited by the processing unit 310 for the execution of programs and for temporary storage of data, and a Read Only Memory (ROM) 320 stores a basic program for the bootstrap of the control unit 160 , as well as other relevant data to be preserved when the control unit 160 is off. The control unit 160 is coupled with the pressure sensor PRS and the temperature sensor TES through respective circuit interfaces 325 , 330 , which include conditioning circuits (such as sample-and-hold circuits, A/D converters, amplifiers, buffers and the like) adapted to treat the signals generated by the sensors PRS, TES for making them interpretable by the processing unit 310 . Using specific algorithms and performing operations (such as calculation of mean values of certain physical quantities) that will be described in the following of the present description, the processing unit 310 processes data received from the sensors PRS, TES, and accordingly drives the supply block 135 for activating the glow plugs GLP through a supply driver circuit 335 .
It is pointed out that some of the components shown in FIG. 3 may be absent in some specific types of control units, and/or additional units may be provided, depending on the specific implementation of the present invention.
According to an embodiment of the present invention, the filter regeneration process (and, in particular, the timing of the glow plugs GLP activation) is managed in a more efficient way exploiting information parameters deducible from the physical quantities (pressure, temperature) monitored by the pressure sensor PRS and the temperature sensor TES.
Very useful information parameters are obtainable from the pressure monitored by the pressure sensor PRS. Particularly, a first useful parameter obtainable from physical quantity monitored by the pressure sensor PRS is the load of PM that has accumulated in the DPF 125 during the use of the vehicle. Generally speaking, the higher the PM load, the higher the counter-pressure generated by the flow FLin of exhaust gas when passing through the DPF 125 , because of the obstruction of the gas flowing channels FLCH. Moreover, it has to be appreciated that the higher the load of PM in the DPF 125 , the higher the combustible material available within the filter to be burned during the regeneration. Thus, the efficiency of the regeneration process may be also favored by a DPF 125 that is highly loaded. As disclosed in the foregoing, an efficient way to quantify the PM load accumulated in the DPF 125 provides for calculating the average value of the counter-pressure values sensed by the pressure sensor PRS, hereinafter referred to as PRm; the average pressure value is calculated over a number NS of samples of the pressure values sensed by the pressure sensor PRS. For this purpose, the interface 325 of the control unit 160 may sample the value monitored by the pressure sensor PRS at a specific sample rate, e.g., every ten seconds, storing the sampled values into the working memory 315 , so as to create a log of pressure values, including a number NS of samples, which may depend on the storage capability of the working memory 315 ; for example, the number NS of samples in the pressure values log may be 200 . The average counter pressure PRm is then calculated by the processing unit 310 using the pressure values in the sample log.
Based on the pressure values sensed by the pressure sensor PRS it is also possible to derive an indication of the flow rate of the exhaust gas. The flow rate of the exhaust gas, and particularly that of the flow FLin at the input of the DPF 125 depends on the load of the engine 105 and on its Revolutions-Per-Minute (RPM), which depend in turn on the current driving condition of the vehicle 100 . The flow rate of the flow Flin negatively affects the triggering of the combustion of the PM and that of the regeneration process, since the higher the flow rate of the flow Flin, the more heat is removed from the DPF 125 . The flow rate of the flow Flin can be monitored based on the instantaneous value PRi of the counter-pressure generated by the flow Flin, which directly depends thereon. The instantaneous value of the pressure PRi is stored in the working memory 315 of the control unit 160 , and is continuously updated as new sample values are received from the pressure sensor PRS through the interface 325 .
Another useful parameter is the DPF temperature. The temperature of the DPF 125 depends on the temperature of the exhaust gas, the flow rate thereof and the thermal inertia of the DPF itself As a result of several experimental proofs, even in presence of glow plugs GLP that heat localized portions of the DPF 125 , the Applicant has observed that the remaining portions of the DPF 125 need to be at a temperature at least higher than a lower threshold temperature Tlow (of the order of 150° C.), otherwise the regeneration process (i.e., the burning of the PM) would not be triggered in a sufficient way. Particularly, if the DPF 125 is at temperatures lower than Tlow, even if the glow plugs GLP were be successful in triggering the burning of the PM accumulated near the glow plugs GLP, the combustion of the PM would not propagate toward the rest of the DPF 125 , even in presence of an additive in the fuel. The higher the DPF temperature with respect to the lower threshold temperature Tlow, the higher the probability that the combustion of the PM propagates through the whole DPF 125 . Since a DPF made of SiC has a high thermal inertia, a good way for obtaining a stable measure of the DPF temperature consists in monitoring the temperature of the flow FLout—hereinafter referred to as Tfl—outputted by the DPF itself In this way, the monitored temperature Tfl results to be essentially independent from any undesired rapid fluctuations introduced by any external factor (unlike the temperature of the flow Flin, which varies quickly); in other words, thanks to the thermal inertia of the DPF 125 , the control unit 160 does not have to perform any average operation, being sufficient to store in the working memory 315 and continuously updating a sample of the temperature value Tfl provided by the interface 330 coupled with the temperature sensor TES.
As better described later, according to an embodiment of the present invention the regeneration process of the DPF 125 is managed in an efficient way taking into account the values of at least two of the three parameters previously introduced, and particularly the average pressure PRm and the instantaneous pressure PRi. As will be described in the following of the present description, according to an embodiment of the present invention the activation of the heating device 127 (i.e., of the glow plugs GLP) is conditioned to the fact that the values of the parameters PRm and PRi exceeds predetermined thresholds, and/or fall in respective ranges; moreover, for further improving the efficiency of the regeneration process, it is possible to condition the activation of the heating device 127 to the fact that the value of the instantaneous temperature Tfl falls in a respective range, too.
More particularly, FIG. 4A depicts a flow chart 400 illustrating the main operations performed by the filter regeneration control system according to an embodiment of the present invention—and in particular by the control unit 160 —on a vehicle 100 . As described in the following, according to an embodiment of the present invention two different types of filter regeneration process are envisaged, and particularly an automatic filter regeneration process, totally managed by the filter regeneration control system during the operation of the vehicle 100 , and an emergency regeneration process—performed with the active involvement of the driver, or a technician of a service center—to be performed in case the automatic filter regeneration process has not given satisfactory results.
The control unit 160 firstly checks whether the vehicle 100 is running (block 405 ), for example according to a signal taken from the alternator (not shown in the figures) of the engine 105 of the vehicle 100 . Alternatively, the control unit 160 may assess whether or not the engine 105 is turned on by detecting the presence or absence of the flow Flin of exhaust gas generated by the engine 105 when turned on; this can be achieved by monitoring the instantaneous pressure PRi.
Having assessed that the engine 105 is turned on (block 405 , exit branch “Y”), the control unit 160 performs a first control (“pressure alarm control”) on the values of the average pressure PRm and the instantaneous pressure PRi. Particularly, this control is performed for determining if the condition of PM load of the DPF 125 are so serious (from a PM occlusion point of view) to require a manual emergency regeneration process.
Particularly, the pressure alarm control (block 410 ) provides for a joint control on both the average pressure PRm and the instantaneous pressure PRi. If the value of the instantaneous pressure PRi remains within a range defined by a minimum alarm instantaneous pressure LAPRi (lower threshold) and a maximum alarm instantaneous pressure HAPRi (higher threshold) for a predetermined alarm time interval Δtall, and at the same time the value of the average pressure PRm belongs to a range defined by a minimum alarm average pressure LAPRm (lower threshold) and a maximum alarm average pressure HAPRm (higher threshold), then the control unit 160 assesses that the DPF 125 is excessively loaded by PM, and that the DPF 125 needs a (manual) emergency regeneration process. Both the maximum alarm instantaneous pressure HAPRi and the maximum alarm average pressure HAPRm may be set to the maximum pressure value that the pressure sensor PRS can sense (full-scale value). Since, as mentioned in the foregoing, the average pressure PRm is directly related to the load of PM accumulated in the DPF 125 , the minimum alarm average pressure LAPRm is advantageously set to a value corresponding to a high load of PM accumulated in the DPF 125 , but sufficiently low not to completely compromise the vehicle 100 operation (i.e., a value that ensures that the DPF 125 is not so loaded by PM that the engine 105 cannot efficiently run). Since also the instantaneous pressure PRi is related to the load of PM (the counter-pressure generated by the flow FLin of exhaust gas when passing through the DPF 125 depends on the PM accumulated in the DPF 125 ), also the minimum alarm instantaneous pressure LAPRi is advantageously set to a value corresponding to a relatively high load of PM accumulated in the DPF 125 ; in this way, a double check is made before deciding that the emergency regeneration has to be performed.
If the previous conditions are satisfied (exit branch “Y” of block 410 ), the filter regeneration control system signals an alarm condition; for example, the control unit 160 notifies the alarm condition to the vehicle driver through a corresponding signaling light on the dashboard (not shown in the figures). The vehicle driver should react to the signaled alarm condition by taking the steps necessary for performing the emergency regeneration process (block 415 ).
The emergency regeneration process may for example provide that the vehicle driver drives the vehicle 100 at a relatively high speed possible for about 10 minutes (compatibly with the traffic conditions and the speed limit restraints).
In this way, the temperature of the DPF 125 reaches a temperature favorable for the combustion of the PM included therein. At this point, the vehicle's march is arrested, and the engine 105 is set to the idling condition. Then, the driver manually controls the activation of the heating device 127 , for example by means of a suitable switch (not shown in the figures) on the cockpit of the vehicle 100 connected to the control unit 160 . The control unit 160 then drives the supply block 135 through the supply driver circuit 335 , in such a way as to turn on the glow plugs GLP of the heating device 127 . After a time that may depend on the glow plug type (for example, 20 seconds), the temperature of the heating elements HE contacting the input base BI of the DPF 125 reaches a substantially steady temperature of about 900° C. The PM accumulated in the DPF 125 in the proximity of the heating elements thus reaches the burning temperature for spontaneous combustion (for example, 350° C. in presence of fuel additive). Since the DPF 125 has been previously brought to a sufficiently high temperature by driving the vehicle 100 at high speed for about 10 minutes, the combustion of the PM propagates through the whole DPF filter 125 .
After a predetermined amount of time, sufficient for allowing the average pressure PRm to adapt to the new condition of the DPF 125 after the activation of the glow plugs GLP (for example, 30 minutes), the control unit 160 checks whether the emergency regeneration has been successful or not (block 420 ). Particularly, the control unit 160 controls if the value of the average pressure PRm after the emergency regeneration still falls within the range defined by the minimum alarm average pressure LAPRm and the maximum alarm average pressure HAPRm or not.
In the affirmative case (exit branch “Y” of block 420 ), the control unit 160 decides that emergency regeneration was not successful, since the value of the average pressure PRm is still too high (this meaning that the PM included in the DPF 125 is still too high); the control unit 160 then increments a regeneration failure counter Nreg (block 425 )—used to count the number of unsuccessful emergency regenerations—and checks if said counter has reached or not a maximum regeneration failure number MAXNreg (block 430 ). In the affirmative case (exit branch “Y” of block 430 ), the DPF 125 needs to be unmounted from the vehicle 100 for being substituted or fixed at a maintenance service center (block 435 ), since performing other emergency regenerations would be useless. On the contrary, if the regeneration failure counter Nreg is still lower then the maximum regeneration failure number MAXNreg (exit branch “N” of block 430 ), the operation flow returns to block 405 for performing again the pressure alarm control.
If instead the value of the average pressure PRm after the emergency regeneration has been assessed to be lower than the minimum alarm average pressure (exit branch “N” of block 420 ), the control unit 160 decides that the emergency regeneration has been successful; indeed, the fact that the value of the average pressure PRm is lower than the minimum alarm average pressure LAPRm means that the PM included in the DPF 125 has been burned out to a sufficient extent. In this latter case, the regeneration failure counter Nreg is reset to zero (block 440 ), and the emergency regeneration procedure is terminated (the operation flow returns to block 405 ).
During the normal operation of the vehicle 100 , i.e., when the DPF 125 is not so occluded by PM to an extent such as to bring the filter regeneration control system in an alarm condition, the control unit 160 manages control operations for determining the when to activate the heating device 127 (i.e., the glow plugs GLP), in such a way that an efficient regeneration process is triggered.
Particularly, the control unit 160 monitors the current values of the average pressure PRm and the instantaneous pressure PRi, checking if said values are all within respective value ranges (block 445 ), and then activating or not the glow plugs GLP based on the result of said check.
Particularly, if:
the value of the instantaneous pressure PRi is higher than a minimum instantaneous pressure LPRi (lower threshold), and the value of the average pressure PRm is higher than a minimum average pressure LPRm (lower threshold),
the control unit 160 determines that the glow plugs GLP can be activated for attempting a regeneration (exit branch “Y” of block 445 ), otherwise the glow plugs are not activated (exit branch “N” of block 445 , returning to block 405 ).
Preferably, according to a further embodiment of the present invention, an optional check is performed on the instantaneous temperature Tfl too. Particularly, in said embodiment the glow plugs GLP are activated when the above-mentioned conditions on the instantaneous pressure PRi and the average pressure PRm are fulfilled, and at the same time if the value of the instantaneous temperature Tfl remains within an interval defined by a minimum instantaneous temperature LT (lower threshold) and a maximum instantaneous temperature HT (higher threshold) for a predetermined time interval Δt(T)
When the conditions above are fulfilled, it is likely that the conditions of the DPF 125 are such as to ensure the triggering of a probable efficient regeneration process if the glow plugs GLP are activated at that moment. Particularly, in order to be in a good condition for an efficient regeneration process, which ensures at the same time not to unnecessarily activate the glow plugs GLP and wasting battery electric power, the average pressure PRm should be higher than a minimum value (LPRm), since a too low average pressure PRm indicates that it is still not necessary to regenerate the DPF 125 and/or that the quantity of PM in the DPF 125 is not sufficient for guaranteeing an efficient PM combustion. The check on the instantaneous pressure PRi is made in order to derive an indication of whether, at the moment the glow plugs will be activated, the engine RPM is likely to be high or low; moreover, the instantaneous pressure PRi gives a useful confirmation about the DPF 125 overload condition. The value of the instantaneous pressure PRi is related to the flow Flin of the exhaust gas at the input of the DPF 125 . Since the higher the flow rate of the flow Flin, the higher the heat removal rate from the DPF 125 , the glow plugs GLP should be activated when the flow FLin is as small as possible. However, based on experimental trials, the Applicant has found that, especially in the urban driving condition, i.e., in the condition in which the filter regeneration favored by the glow plugs activation is mostly necessary, after relatively high peaks of instantaneous pressure PRi, corresponding to relatively high flow Flin generated by a sudden increase of the engine RPM, the instantaneous pressure PRi (and correspondingly the flow Flin) falls (because the engine RPM decrease). Thus, every time a relatively high peak of instantaneous pressure PRi is detected, i.e., when the value of the instantaneous pressure PRi has exceeded the minimum instantaneous pressure LPRi, it is likely that the flow FLin of exhaust gas will subsequently decrease during the time interval in which the glow plugs GLP are turned-on, a condition favorable for the combustion of the PM.
The optional check on the instantaneous temperature Tfl may be performed for assessing if the temperature of the DPF 125 is sufficiently high for allowing the propagation of the PM combustion through the whole DPF 125 (Tfl>LT), and at the same time if it is lower than a maximum value (HT), above which the activation of the glows plugs GLP would be unnecessary, since the PM would burn for spontaneous combustion.
In case the control unit 160 has assessed that the conditions are suitable for the activation of the heating device 127 , it drives the supply driver circuit 335 to activate the glow plugs GLP (block 450 ) for an amount of time, referred to as activation interval Ton. It has been found that a duration of the activation interval Ton set in the control unit 160 in order to be sufficiently compliant with the need of at least locally initiating the PM combustion, advantageously allows the instantaneous pressure PRi to fall from the value higher than the minimum instantaneous pressure LPRi that has triggered the activation of the glow plugs GLP to a lower value corresponding to a low flow Flin of exhaust gas, which is favorable to the propagation of the combustion of the PM in the DPF 125 .
More particularly, the combustion of the PM in the DPF 125 is not an instantaneous event, since the burning of the PM initially occurs only in the portions of the DPF 125 close to the glow plugs GLP; as a consequence, the burning of the PM requires an amount of time to propagate through the whole DPF 125 . Taking into account this consideration, the Applicant has observed that the “slowness” of the burning propagation can be advantageously exploited for guaranteeing with a good probability that the regeneration process is performed when the flow FLin of the exhaust gas produced by the engine 105 is sufficiently low, when there is no substantial obstacle to the propagation of the combustion of the PM to the whole filter.
When the condition on the average pressure PRm is fulfilled—and thus the value thereof is higher than the minimum average pressure LPRm—, it means that a regeneration of the DPF 125 is recommended, and the load of PM accumulated therein is sufficient for guaranteeing a good PM combustion.
It has to be appreciated that the value of the average pressure PRm increases with a substantially slow rate, being calculated by means of an average over the NS samples of the pressure values collected by the control unit 160 through the pressure sensor PRS. Unlike the average pressure PRm, the instantaneous pressure PRi (and thus the flow FLin of the exhaust gas) can vary rapidly in time, depending on the load of the engine 105 and on its Revolutions-Per-Minute (RPM), which depend in turn on the current driving condition of the vehicle 100 . Thus, having assessed through the fulfilment of the condition on the average pressure PRm that the DPF 125 needs a regeneration, the event that actually triggers the activation of the glow plugs GLP is the fulfilment of the condition on the instantaneous pressure PRi. Particularly, substantially as soon as the instantaneous pressure PRi reaches the minimum instantaneous pressure LPRi, the control unit 160 drives the supply block 135 for activating the glow plugs GLP; since the burning of the PM is not instantaneous, but requires an amount of time to propagate through the whole DPF 125 , the glow plugs GLP are kept activated during the activation interval Ton, in such a way as to leave to the instantaneous pressure PRi the time to fall to a significantly lower value, corresponding to a low flow Flin of exhaust gas. As will be described in detail in the following of the present description, setting the minimum instantaneous pressure LPRi to a value sufficiently high (statistically improbable) to be reached by the instantaneous pressure PRi only during the high peaks thereof that are generated by a sudden increase of the engine RPM, and considering that every time a relatively high peak of instantaneous pressure PRi is detected, it is likely that the flow FLin of exhaust gas will subsequently decrease, it is possible to guarantee with a good probability that the regeneration process be successfully performed. The duration of the activation interval Ton is properly set in such a way to be sufficiently sure that the glow plugs GLP are still activated when the flow FLin of exhaust gas has reached a low level. Thus, the choice of activating the glow plugs GLP when the instantaneous pressure PRi has a high value, which at a glance would seem unfavorable for the outcome of the regeneration process, is really advantageous, since at least a portion of the activation interval Ton necessary for the instantaneous pressure PRi to reach a low value corresponding to a low flow FLin of exhaust gas may correspond to the time needed for the burning of the PM to propagate in the whole extent of the DPF 125 . Moreover, it has to be appreciated that the activation interval Ton may include at least the time spent by the glow plugs GLP after their activation to reach a temperature sufficiently high to trigger the combustion of the PM.
Returning back to a flow chart 400 illustrated in FIG. 4A , the control unit 160 then checks if the regeneration process has been successful or not. Particularly, after a predetermined amount of time, sufficient for allowing the average pressure PRm to adapt to the new condition of the DPF 125 after the activation of the glow plugs GLP (for example, 30 minutes), the control unit 160 controls if the value of the average pressure PRm after the regeneration is still higher than the minimum average pressure LPRm or not (block 455 )
If the value of the average pressure PRm after the regeneration is lower than the minimum average pressure LPRm (exit branch “N” of block 455 ), the control unit 160 determines that the regeneration process has been successful, while in the opposite case, the regeneration process has not been successful (exit branch “Y” of block 455 ). In both cases, after the regeneration process the control unit 160 again checks if it is necessary a manual emergency regeneration process (returning to block 405 and then to block 410 ). However, in case the control unit 160 has determined that the regeneration process has been successful, the regeneration failure counter Nreg is reset to zero (block 460 ). According to an embodiment of the present invention, the control unit 160 may perform further operations directed to optimize the values of the minimum average pressure LPRm for improving the efficiency of the filter regeneration process based on information collected by the control unit 160 after the glow plugs have been activated. A description of said operations will be provided in the following of the description (particularly, in connection to FIG. 6 ).
All the operations that have been described with reference to FIG. 4A may be performed by the control unit 160 by executing a sequence of instructions of a firmware stored in the control unit 160 itself—for example, in the ROM 320 —and executed by the processing unit 310 .
FIG. 4B depicts a diagram 465 showing an exemplary evolution in time of the instantaneous pressure PRi during the vehicle 100 operation. Particularly, the abscissa of the diagram 465 indicates the time, while the ordinate indicates the value of the instantaneous pressure PRi. The instantaneous pressure PRi has an oscillating trend, following the RPM of the engine 105 , with an average value that increases in time (due to the increase of the PM load in the DPF 125 , that causes a constant increase of the average pressure PRm). After a relatively high peak in the instantaneous pressure PRi—like the one indicated in FIG. 4B with the reference 470 —, the flow FLin of exhaust gas decreases significantly.
In order to describe in greater detail the evolution in time of the regeneration process, and the relationship occurring between the activation of the glow plugs GLP and the instantaneous pressure PRi according to an embodiment of the present invention, reference will be now made to FIG. 4C .
Particularly, FIG. 4C depicts a first diagram 475 showing an exemplary evolution in time of the instantaneous pressure PRi and a second diagram 480 showing an exemplary evolution in time of the instantaneous temperature Tfl during the activation of the glow plugs GLP and the triggering of the regeneration process of the DPF 125 . For example, the evolution in time of the instantaneous pressure PRi shown in the diagram 475 may correspond to a portion of that shown in the diagram 465 illustrated in FIG. 4B , and particularly a portion including the high peak 470 .
It is supposed that at the time corresponding to the beginning of the diagrams 475 and 480 the average pressure PRm is higher than the minimum average pressure LPRm, meaning that the DPF 125 needs a regeneration, and the load of PM accumulated therein is sufficient for guaranteeing a good PM combustion. As previously described, in this condition the event that triggers the activation of the glow plugs GLP is the fulfilment of the condition on the instantaneous pressure PRi.
As soon as the instantaneous pressure PRi reaches the minimum instantaneous pressure LPRi (time t 0 ), the control unit 160 drives the supply block 135 for activating the glow plugs GLP. As will be described in the following of the present description, the minimum instantaneous pressure LPRi is set by the control unit 160 to a value sufficiently high to be reached by the instantaneous pressure PRi only during the high peaks thereof, like the peak identified with the reference 470 . In the example at issue, the instantaneous pressure PRi equals the minimum instantaneous pressure LPRi close to the upper portion of the peak 470 , and particularly briefly before the top thereof.
After the activation of the glow plugs GLP at the time t 0 , the temperature thereof starts to increase, reaching a substantially steady temperature at a subsequent time t 1 that depends on the glow plug type. For example, a typical glow plug GLP may reach a steady temperature of about 900° C. in about 20 seconds.
Based on the results of several experimental proofs, the Applicant has observed that the high peaks of instantaneous pressure PRi typically have a quite short duration, and particularly much lower than the time needed for the glow plugs GLP to reach the steady temperature after the activation. For example, in the urban driving condition, a relatively high peak of instantaneous pressure PRi that corresponds to a relatively high flow Flin generated by a sudden increase of the engine RPM, may have a duration in time of the order of 2-5 seconds. In the example at issue, the instantaneous pressure PRi falls from the value corresponding to the top of the peak 470 to about one third of said value in about 2 seconds (time t 2 ). This means that, by properly setting the minimum instantaneous pressure LPRi, the glow plugs GLP are activated few seconds before the reaching of a local minimum of the instantaneous pressure PRi, which corresponds to a low flow Flin of exhaust gas. In other words, when the DPF 125 is in a condition favorable for the combustion of the PM, with the proposed solution the glows plugs GLP are already activated, and the regeneration process may be performed correctly with a high probability.
The PM in the DPF 125 initially starts to burn locally, in the portions of the DPF 125 close to the glow plugs GLP. The time corresponding to the beginning of the local burning (time t 3 ) depends on several factors, like the actual temperature of the flow Flin, the load of PM, and the presence of additives added to the fuel and remaining in the exhaust gases. The time t 3 corresponding to the beginning of the local burning may occur before the time t 1 at which the glow plugs GLP reach the steady temperature, but likely after the time t 2 at which the instantaneous pressure PRi reaches a local minimum. In the example at issue, the local burning begins at a time t 3 equal to about 10-18 seconds after the time to.
As time goes by, the burning of the PM propagates, until substantially involving the whole extent of the DPF 125 (time t 4 ). Also the time t 4 at which the burning of the PM can be considered to have substantially propagated through the whole DPF 125 depends on several factors, like the actual temperature of the flow Flin, the load of PM and the size of the DPF 125 itself. In the example at issue, said time t 4 occurs about 30-35 seconds after the time t 0 .
A good parameter that can be used for assessing if the regeneration process has been correctly triggered, i.e., if the burning of the PM has occurred substantially in most of the DPF 125 is the instantaneous temperature Tfl sensed by the temperature sensor TES, i.e., the temperature of the flow outputted by the DPF 125 . Thanks to the thermal inertia of the DPF 125 , the instantaneous temperature Tfl starts to significantly increase only a non-negligible time period after the time t 3 corresponding to the beginning of the local burning. In the example at issue, the instantaneous temperature Tfl starts to increase few second before the time t 4 at which the burning of the PM has reached the whole extent of the DPF 125 .
In order to avoid any unnecessary waste of battery electric power, once the burning of the PM has been sufficiently propagated across the DPF 125 , the glow plugs GLP may be deactivated, since at this time, the burning of the PM is auto-sustained, and is capable of continuing without the need of the additional heat provided by the glow plugs GLP.
According to an embodiment of the present invention, the glow plugs GLP are turned off by the control unit 160 at a time t 5 corresponding to a relatively high increasing rate of the instantaneous temperature Tfl (i.e., when the slope of the curve depicting the instantaneous temperature Tfl is sufficiently high, exceeding a predetermined threshold slope). Indeed, for the reasons previously described, at this time t 5 it is possible to asses—with a high probability that the burning of the PM has been sufficiently propagated across the DPF 125 , and that the burning is able to continue without the need of the additional heat provided by the glow plugs GLP. In the example at issue, the time t 5 at which the glow plugs GLP are turned off occurs few seconds after the time at which the burning of the PM is involving the whole extent of the DPF 125 , and particularly about 40 seconds after the time t 0 .
In other words, according to an embodiment of the present invention, the glow plugs GLP are kept activated for an activation interval Ton starting from a time t 0 close to the occurrence of the top of an instantaneous pressure PRi peak, and terminating at a time t 5 corresponding to a relatively high increasing rate of the instantaneous temperature Tfl.
In order to improve the efficiency, according to an embodiment of the present invention, the filter regeneration system performs the above described controls on the current values of the instantaneous pressure PRi, the average pressure PRm and the instantaneous temperature Tfl using threshold values that are optimized for the specific vehicle 100 and for its driving conditions.
According to an embodiment of the present invention, the threshold values used by the control unit 160 for assessing when to activate the glow plugs GLP are adjustable. Preferably, the threshold values used by the control unit 160 for assessing when to activate the glow plugs GLP are automatically determined by the control unit 160 itself during the vehicle 100 operation, fitting them to the particular driving conditions of the moment.
Regarding in particular the instantaneous pressure, a way for improving the efficiency of the filter regeneration process is to dynamically adjust the value of the minimum instantaneous pressure LPRi based on the vehicle 100 condition (particularly, based on the driving condition).
During the operation of the vehicle 100 , the control unit 160 dynamically sets the minimum instantaneous pressure LPRi as described in the schematic flowchart 500 of FIG. 5A .
As soon as the engine 105 of the vehicle 100 is started, the control unit 160 begins to collect samples of the instantaneous pressure PRi (block 510 ). As the control unit 160 collects PRi samples, a pressure sample log—including a number PNS of samples (for example, 200 )—is progressively filled to generate a statistical distribution of instantaneous pressures PRi. An example of such a distribution is shown in FIG. 5B with the reference DP(i), wherein the abscissa indicates the possible values of the instantaneous pressure PRi that can be sampled during the operation of the vehicle 100 , and the ordinate indicates the frequency of samples for each pressure value.
The control unit 160 sets the value of the minimum instantaneous pressure LPRi using the information obtainable from the distribution DP(i) corresponding to the actual pressure sample log (block 520 ). More particularly, the control unit sets the minimum instantaneous pressure LPRi to a high improbable pressure value corresponding to a relatively high percentile (e.g., the 90th, and preferably the 95th percentile) of the distribution DP(i), in such a way to select a pressure corresponding to a high peak. Alternatively, the control unit 160 may firstly select from the PNS samples of the pressure sample log, those samples that correspond to instantaneous pressures PRi higher than the average pressure PRm for generating a corresponding further statistical distribution of instantaneous pressures PRi, and then set the value of the minimum instantaneous pressure LPRi to a pressure value corresponding to said relatively high percentile of the further statistical distribution.
Then, the pressure sample log is updated with new, incoming PRi samples (block 530 ), and the process is reiterated (returning to block 510 ). Particularly, the control unit 160 updates the sample log with a number (possibly one) of new PRi samples, removing therefrom a corresponding number of the oldest PRi samples, and recalculates the minimum instantaneous pressure LPRi on the basis of the distribution obtained with the new sample log.
In order to further improve the efficiency of the proposed filter regeneration system, the possibility may also be contemplated that, in operation, the control unit 160 varies the value of the percentile of the distribution DP(i) used for setting the minimum instantaneous pressure LPRi, so as to better fit the expected driving condition of the vehicle 100 .
According to an embodiment of the present invention, also the value of the minimum average pressure LPRm may be dynamically determined by the control unit 160 in an automatic way to improve the filter regeneration process based on the vehicle 100 operating condition (and in particular based on the DPF 125 condition).
Making reference to the flow chart 600 illustrated in FIG. 6 , the operations which are shown in the flow chart 600 are performed during the vehicle 100 operation, and integrate the operations of the control unit 160 shown in the flow chart 400 of FIG. 4A . For this reason, the blocks corresponding to those shown in the FIG. 4A are denoted with the same references, and their explanation is omitted for the sake of brevity
The control unit 160 stores, for example in the ROM 320 , default values for the minimum average pressure (block 605 ). Particularly, the minimum average pressure LPRm may be instead initially set to a default minimum average pressure DLPRm corresponding to a relatively high value, in such a way to avoid that, at the beginning of the vehicle 100 operation, the glow plugs GLP are unnecessarily activated even when the PM accumulated in the DPF 125 is low (indeed, the value of the average pressure PRm is directly related to the PM blockage of the DPF 125 ).
At this point, the control unit 160 performs the normal operations previously described in connection with FIG. 4A for determining whether to activate the glow plugs GLP (blocks 445 , 450 ), and then checks if the regeneration process has been successful or not, by controlling if the value of the average pressure PRm after the regeneration is still higher than the minimum average pressure LPRm or not after a predetermined amount of time (block 455 ).
In case the value of the average pressure PRm is still higher than the minimum average pressure LPRm (exit branch “Y” of block 455 ), meaning that the regeneration process has not been successful, the control unit 160 increments a regeneration fault counter NRf, for example stored in the working memory 315 (block 610 ). At this point, the control unit 160 checks if the value of said regeneration fault counter NRf has reached or not a preset regeneration fault threshold TNRf (block 620 ). If the regeneration fault counter NRf results to be lower than the regeneration fault threshold TNRf (exit branch “N” of block 620 ), no further additional operation is performed on the minimum average pressure LPRm, and the operation flow of the control unit 160 returns to block 445 . If instead the regeneration fault counter NRf reaches the value of the regeneration fault threshold TNRf (exit branch “Y” of block 620 ), it means that a number TNRf of consecutive activations of the glow plugs GLP has not been successful. In this case, the minimum average pressure LPRm is increased (for example by a predetermined amount, and until a predetermined maximum value, e.g., corresponding to the default minimum average pressure DLPRm), in such a way that the following activation of the glow plugs GLP will be conditioned to a higher average pressure PRm (block 625 ). This means that the regeneration process will be facilitated with respect to the previous cases, since the activation of the glow plugs will occur with a higher load of PM to be combusted. After having increased the minimum average pressure LPRm, the regeneration fault counter NRf is reset to zero, and the operation flow of the control unit 160 returns to block 445 .
In case instead after the activation of the glow plugs GLP the value of the average pressure PRm has fallen below the minimum average pressure LPRm (exit branch “N” of block 455 ), meaning that the regeneration process has been successful, the control unit 160 increments a regeneration successful counter NRs, for example stored in the working memory 315 (block 630 ). The control unit 160 then checks if the value of said regeneration successful counter NRs has reached or not a preset regeneration successful threshold TNRs (block 635 ). If the regeneration successful counter NRs is lower than the regeneration successful threshold TNRs (exit branch “N” of block 635 ), no further additional operation is performed on the minimum average pressure LPRm, and the operation flow of the control unit 160 returns to block 445 . If instead the regeneration successful counter NRs has reached the value of the regeneration successful threshold TNRs (exit branch “Y” of block 635 ), it means that a number TNRs of consecutive activations of the glow plugs GLP has been successful. In this case, the minimum average pressure LPRm is decreased (for example by a predetermined amount, and down to a predetermined minimum value), in such a way that the subsequent activation of the glow plugs GLP will be conditioned to a lower average pressure PRm (block 640 ). This means that the subsequent activation of the glow plugs will occur with a lower load of PM to be combusted, since it is likely that the previous activations of the glow plugs GLP have been performed with an excessive PM load. After having decreased the minimum average pressure LPRm, the regeneration successful counter NRs is reset to zero, and the operation flow of the control unit 160 returns to block 445 .
According to a further embodiment of the present invention, the procedure for dynamically determining the minimum average pressure LPRm can be further improved, by conditioning the extent of the increments/decrements of the minimum average pressure LPRm to the variation of the average pressure PRm after the activation of the glow plugs GLP. Particularly, based on the extent of the variation of the average pressure PRm after the activation of the glow plugs GLP, it is possible to quantify the extent to which the regeneration process has been successful/unsuccessful. For example, if the activation of the glow plugs GLP gives as a result only a little decrease of the average pressure PRm, it means that said activation has triggered the combustion of only a little fraction of the PM included in the DPF 125 . If instead the activation of the glow plugs GLP has given as a result a greater decrease of the average pressure PRm, it means that said activation has triggered the combustion of a greater fraction of the PM included in the DPF 125 . Based on these considerations, instead of increasing/decreasing the minimum average pressure LPRm by fixed amounts, as previously described with reference to FIG. 6 , the increments/decrements may be a function of the variation of the average pressure PRm. For example, the control unit 160 may calculate the variation of the average pressure PRm by subtracting the value of the average pressure PRm after an activation of the glow plugs GLP from the value of the average pressure PRm before the activation of the glow plugs GLP, and then using said value for weighing preset increment and decrement amounts.
According to an embodiment of the present invention, the minimum instantaneous temperature LT and the maximum instantaneous temperature HT, as well as the other thresholds set for the average and instantaneous pressure, may be determined starting from preliminary experimental results, obtained through test campaigns performed on the field, for example on a test vehicle corresponding to the vehicle 100 on which the system is intended to be installed.
FIG. 7A illustrates the experimental results obtained through an exemplary test campaign. Samples of the instantaneous temperature Tfl of the DPF 125 are collected by monitoring the test vehicle in two distinct operating conditions, namely a “urban” condition, which is unfavorable for the natural PM combustion, in which the test vehicle is driven essentially in a urban scenario, at relatively low speeds and with frequent stops, and a “highway” condition, favorable for the PM combustion, wherein the test vehicle is driven essentially continuously at relatively high speeds, with few stops.
FIG. 7A shows a diagram 700 in which the abscissa indicates the instantaneous temperature Tfl of the DPF, and the ordinate indicates the frequency of samples taken during the test campaign. The samples statistical distribution corresponding to the urban condition—denoted in FIG. 7A with reference 710 —is centered around a low temperature value (for example, 120° C.), while the samples statistical distribution corresponding to the highway condition—indicated in FIG. 7A with the reference 720 —is centered around a higher temperature value (for example, 370° C.). This is a reasonable outcome, since in the urban condition the vehicle 100 is subjected to low stresses, and the engine 105 essentially works at low RPM, while in the highway condition the engine works at higher RPM.
In order to derive useful values for the temperature thresholds, i.e. the minimum instantaneous temperature LT and the maximum instantaneous temperature HT, the statistical distributions 710 and 720 are compared with two temperature threshold, namely a low temperature threshold ALT corresponding to the minimum temperature of the DPF 125 that allows the PM combustion to propagate through the DPF 125 once triggered by the glow plugs GLP (e.g., 150° C.), and a high temperature threshold AHT corresponding to the temperature above which the PM burns for self combustion and the activation of the glow plugs GLP is no longer necessary for triggering the PM combustion (e.g., 350° C.,).
Comparing such two low and high temperature thresholds ALT and AHT with the distributions 710 and 720 , it is possible to infer that the low temperature threshold ALT corresponds to a relatively high percentile of the distribution 710 (for example, higher than the 70th percentile and preferably equal to approximately the 95th percentile), while the high temperature threshold AHT corresponds to a relatively low percentile of the distribution 720 (for example, lower than the 45th percentile and preferably equal to approximately the 30th percentile).
In a practical case (like during the operation of the control unit 160 ), said statistical distribution of the temperature value samples will generally differ from both the distribution 710 and the distribution 720 , for example because before reaching a highway, the vehicle 100 first travel in a scenario similar to that corresponding to the urban condition, represented by the distribution 720 . An example of a more close-to-reality statistical distribution is indicated in FIG. 7A with the reference 730 . It can be observed that the distribution 730 is less regular, being more spread across a wider range of temperature values extending from those corresponding to the distribution 710 to those corresponding to the distribution 720 .
Based on statistical computations, it is possible to deduce the percentiles of the distribution 730 that correspond to the minimum instantaneous temperature LT and the maximum instantaneous temperature HT using the percentiles corresponding to the temperature thresholds ALT, AHT of the distributions 710 and 720 , respectively, with a good approximation. For example, starting from a low temperature threshold ALT corresponding to the 95th percentile of the distribution 710 and from a high temperature threshold HLT corresponding to the 45th percentile of the distribution 720 , a good approximation may give as a result a minimum instantaneous temperature LT corresponding to the 30th percentile and a maximum instantaneous temperature HT corresponding to the 70th percentile of the distribution 730 .
However, the Applicant has observed that even if the temperatures of the distribution 720 lower than but relatively close to that for which the PM burns for self combustion (i.e., 350° C.) are favorable to the PM combustion, and thus would in principle be favorable for the activation of the glow plugs GLP, said range of temperature corresponds to a condition in which no great advantage can be taken by the activation of the glow plugs GLP. Particularly, the temperatures of the distribution 720 that are lower than but relatively close to the temperature for which the PM burns for self combustion may correspond to a condition in which the engine 105 is working at high RPM, which in turn corresponds to a condition in which the flow rate of the flow Flin is relatively high. As already mentioned in the present description, a high flow rate Flin negatively affects the triggering of the combustion of the PM and that of the regeneration process, since the higher the flow rate of the flow Flin, the more heat is removed from the DPF 125 .
In this regard, it has to be appreciated that in those driving conditions wherein the vehicle is driven essentially continuously at relatively high speeds—such as when the vehicle is being driven in a highway environment—, the engine RPM may remain high for a relatively long period of time. Unlike in the urban driving condition, wherein after relatively high peaks of instantaneous pressure PRi the instantaneous pressure PRi (and correspondingly the flow rate of the flow Flin) is likely to fall because the engine RPM decrease, in e.g. highway driving conditions the instantaneous pressure PRi (and, correspondingly, the flow rate of the flow Flin) may not fall to a low value for a long period of time. Thus, in highway driving condition, by activating the glow plugs GLP as soon as the instantaneous pressure PRi has exceeded the minimum instantaneous pressure LPRi, the combustion of the PM may not be correctly triggered, since it is likely that the flow rate of the flow FLin will not subsequently decrease during the time interval in which the glow plugs GLP are turned-on.
Therefore, according to an embodiment of the present invention, it may be useful not to activate the glow plugs GLP when the temperature of the exhaust gas is lower than but relatively close to the temperature for which the PM burns for self combustion, because such a temperature value may correspond to a condition in which the engine 105 works at high RPM, corresponding in turn to a condition in which the flow rate of the flow Flin is relatively high.
As a consequence, according to an embodiment of the present invention, the maximum instantaneous temperature HT may be calculated using a lower percentile of the distribution 720 , for example the 30th percentile or a lower percentile. Thus, even if in this way a range of temperatures which are in principle favorable for the PM combustion (under the temperature point of view) are “discarded”, and the activation of the glow plugs GLP is performed at lower temperatures, it is assured that the glow plugs GLP are activated in a more convenient condition, with a flow rate Flin that is not too high.
According to an embodiment of the present invention, the results obtained from the test campaign are then used by the control unit 160 for dynamically adjusting the minimum instantaneous temperature LT and the maximum instantaneous temperature HT based on the driving condition of the vehicle 100 .
Reference is now made to the flow chart 740 depicted in FIG. 7B , illustrating the operations performed by the control unit 160 , together with a diagram 745 shown in FIG. 7C , in which the abscissa indicates exemplary values of the instantaneous temperature Tfl of the DPF 125 that may be sampled during the operation of the vehicle 100 , and the ordinate indicates the frequency of samples for each instantaneous temperature value.
The control unit 160 stores as configuration parameters, for example in the ROM 320 , the low and high temperature thresholds ALT, HLT, to be used as default temperature threshold values in case the temperature threshold values calculated using the samples taken during the actual vehicle run results unsuitable, as will be described in the following (block 750 ).
When the engine 105 of the vehicle 100 is started, the control unit 160 starts collecting samples of the instantaneous temperature Tfl (block 755 ). As the control unit 160 collects instantaneous temperature Tfl samples, a temperature sample log—including a number TNS of samples (for example, 200 )—is progressively filled to generate a first distribution of instantaneous temperatures Tfl—indicated in FIG. 7C with the reference D(i). As can be observed in FIG. 7C , the distribution D(i) is similar to the distribution 710 corresponding to the urban condition obtained with the preliminary test campaign ( FIG. 7A ). A reason for this is that, at the beginning of any travel, the vehicle 100 is in a condition similar to that represented by the distribution 710 (at the beginning of the travel, the vehicle 100 starts with the engine 105 that is cold, and probably travels in a urban scenario, or at least in a scenario that does not allow reaching high speeds for long periods).
Then, the control unit 160 calculates a tentative minimum instantaneous temperature tLT and a tentative maximum instantaneous temperature tHT, using the percentiles calculated according to the experimental results and stored in the memory 320 as part of the configuration parameters, and applying said percentiles to the distribution D(i). Making reference to the example at issue, the tentative minimum instantaneous temperature tLT is calculated taking the 30th percentile of the distribution D(i), while the tentative maximum instantaneous temperature tHT is calculated taking the 70th percentile of the distribution D(i) (block 760 ). Said tentative values are indicated in the diagram 745 of FIG. 5C with the references tLT(i) and tHT(i).
At this point, the control unit 160 sets the minimum instantaneous temperature LT to the maximum value between the tentative minimum instantaneous temperature tLT and the low temperature threshold ALT, while the maximum instantaneous temperature HT is set equal to the minimum value between the tentative maximum instantaneous temperature tHT and the high temperature threshold AHT (block 765 ). In this way, it is ensured that a tentative minimum instantaneous temperature tLT lower than the low temperature threshold ALT is discarded, since it corresponds to a temperature Tfl lower than the minimum one sufficient for allowing the PM combustion to propagate through the DPF 125 once triggered by the glow plugs GLP (e.g., 150° C.); similarly, it is ensured that a tentative maximum instantaneous temperature tHT higher than the high temperature threshold AHT is discarded, since it corresponds to a temperature Tfl higher than the maximum one for which the activation of the glow plugs GLP is required for activating the PM combustion (e.g., 350° C.) and beyond which the PM burns for self combustion).
Thus, the tentative minimum instantaneous temperature tLT(i) obtained with the exemplary distribution D(i) will be discarded—being lower than the low temperature threshold ALT—, while the tentative maximum instantaneous temperature tHT(i) will be maintained—being lower than the high temperature threshold AHT.
Preferably, if both the tentative minimum instantaneous temperature tLT(i) and the tentative maximum instantaneous temperature tHT(i) are lower than the low temperature threshold ALT, the control unit 160 may set the minimum instantaneous temperature LT to the low temperature threshold ALT and the maximum instantaneous temperature HT to the high temperature threshold AHT. Alternatively, in case both the tentative minimum instantaneous temperature tLT(i) and the tentative maximum instantaneous temperature tHT(i) are lower than the low temperature threshold ALT, the control unit 160 may maintain the minimum instantaneous temperature LT and the maximum instantaneous temperature HT that were calculated in a previous step.
Then, as the vehicle travel proceeds, the temperature sample log is updated with new Tfl samples (block 770 ), and the process is reiterated (returning to block 560 ). Particularly, the control unit 160 updates the sample log with a number (possibly equal to one) of new Tfl samples, removing therefrom a corresponding number of the oldest Tfl samples, and recalculates the tentative minimum instantaneous temperature tLT and the tentative maximum instantaneous temperature tHT using the same percentiles used before but applying them to the new distribution—indicated in FIG. 7C with the reference D(i+1).
In the example of FIG. 7C , the new distribution D(i+1) is wider, for example because the engine 105 is now working at a higher temperature, and the vehicle 100 is traveling at higher speeds. Making still reference to the exemplary distribution D(i+1) of FIG. 7C , the new tentative minimum instantaneous temperature—indicated in FIG. 5C with the reference tLT(i+1) has overtaken the low temperature threshold ALT, while the new tentative maximum instantaneous temperature—tHT(i+1) in FIG. 7C is now higher than the high temperature threshold HLT. Thus, the minimum instantaneous temperature LT will be set equal to the value t 1 T(i+1), while the maximum instantaneous temperature HT will be now equal to the high temperature threshold AHT.
Preferably, if both the tentative minimum instantaneous temperature tLT(i+1) and the tentative maximum instantaneous temperature tHT(i+1) are higher than the high temperature threshold AHT, the control unit 160 may set the minimum instantaneous temperature LT to the low temperature threshold ALT and the maximum instantaneous temperature HT to the high temperature threshold AHT. Alternatively, in case both the tentative minimum instantaneous temperature tLT(i+1) and the tentative maximum instantaneous temperature tHT(i+1) are higher than the high temperature threshold AHT, the control unit 160 may maintain the minimum instantaneous temperature LT and the maximum instantaneous temperature HT that were calculated in a previous step.
All the operations that have been described with reference to FIGS. 7B and 7C are performed by the control unit 160 together with the operations described with reference to FIG. 4A .
Thus, according to an embodiment of the present invention, instead of having fixed temperature threshold values for assessing if the instantaneous temperature Tfl of the DFP 125 is at a favorable level for activating the glow plugs GLP, said thresholds are advantageously determined by the control unit 160 dynamically, so as to fit the actual driving condition of the vehicle 100 .
According to another embodiment of the present invention, the minimum and maximum instantaneous temperature thresholds LT, HT may be set by the control unit 160 using predetermined relationships—e.g., determined during the test campaign and stored in the memory 320 as part of the configuration parameters—which establish the values of the minimum and maximum instantaneous temperature thresholds LT, HT on the basis of where the statistical distribution of the samples of instantaneous temperature is located with respect to the low temperature threshold ALT and the high temperature threshold AHT. The position of the statistical distribution of the samples of instantaneous temperature may be determined by observing which temperature value corresponds to a first percentile of the statistical distribution, relatively higher than the 50th percentile thereof, e.g., the 70th. According to this embodiment, the values of the minimum and maximum instantaneous temperature thresholds LT, HT are set by the control unit 160 according to a relationship that provides the values for the minimum and maximum instantaneous temperature thresholds LT, HT using said first percentile. For example, this relationship may be implemented through a relationship table stored in the memory 320 , which includes, for each value (or for each range of values) that said first percentile may assume in a predetermined range including the low temperature threshold ALT and the high temperature threshold AHT, a corresponding pair of predetermined values for the minimum and maximum instantaneous temperature thresholds LT, HT. Additionally, instead of having fixed, predetermined minimum and maximum instantaneous temperature thresholds LT, HT values, the table may provide—for some values that said first percentile may assume—further percentiles to be calculated again on the statistical distribution of the samples of instantaneous temperature for obtaining the minimum and/or the maximum instantaneous temperature thresholds LT, HT. A possible example of said relationship table, wherein the first percentile is the 70th of the statistical distribution, the low temperature threshold ALT is equal to 150° C. and the high temperature threshold AHT is equal to 350° C., is illustrated in the following:
1st percentile (70th) LT HT 140° C. 150° C. 99th 160° C. 70th 95th 240° C. 40th 80th 260° C. 30th 70th 340° C. 20th 60th 360° C. 10th 350° C.
According to this example, if the 70th percentile of the statistical distribution of the samples of instantaneous temperature is equal (or close) to 140° C. (that is lower than the low temperature threshold ALT, which is 150° C.), the control unit 160 directly sets the minimum instantaneous temperature threshold LT to the low temperature threshold ALT (150° C.), while sets the maximum instantaneous temperature threshold HT to the 99th percentile of the statistical distribution of the samples of instantaneous temperature; if instead the 70th percentile is equal (or close) to 160° C., the control unit 160 sets the minimum instantaneous temperature threshold LT to the 70th percentile of the statistical distribution, while sets the maximum instantaneous temperature threshold HT to the 95th percentile of the statistical distribution, and so on.
According to a still further embodiment of the present invention, the control unit 160 may be capable of inferring, from the statistical distribution of the samples of instantaneous temperature, the vehicle driving condition, and accordingly set the minimum and maximum instantaneous temperature thresholds LT, HT. Exploiting the percentiles calculated as described above, according to the experimental results, and stored in the memory 320 as part of the configuration parameters, the control unit 160 may establish whether the actual statistical distribution of the samples of instantaneous temperature it has collected substantially corresponds to the distribution 710 or to the distribution 720 . For example, in order to establish whether the actual statistical distribution substantially corresponds to the urban distribution 710 , the control unit 160 may calculate the tentative minimum instantaneous temperature tLT, using the 30th percentile stored as configuration parameter: if the calculate tentative minimum instantaneous temperature tLT is significantly lower than the low temperature threshold ALT (e.g., 150 ° C.), then the control unit 160 may decide that the vehicle is being driven in a urban environment, for which the statistical distribution 710 applies; the control unit 160 may in this case take a high percentile, e.g. higher than the 70th, and preferably the 95th of the actual statistical distribution, and calculate the tentative minimum instantaneous temperature tLT. If the calculated tentative minimum instantaneous temperature tLT is lower than the low temperature threshold ALT, the control unit 160 sets the minimum instantaneous temperature tLT equal to the low temperature threshold ALT. If the calculated tentative minimum instantaneous temperature tLT falls within a temperature range defined by the low temperature threshold ALT and a minimum instantaneous temperature upper limit (e.g., 200° C.), the minimum instantaneous temperature tLT is set equal to the calculated tentative minimum instantaneous temperature tLT. If instead the calculated tentative minimum instantaneous temperature tLT is higher than the minimum instantaneous temperature upper limit (this may occur in case the actual statistical distribution is centered around a low temperature, such as 120°-150° C., but has an extended upper tail that corresponds to relatively high temperature values), the minimum instantaneous temperature tLT is set equal to said minimum instantaneous temperature upper limit.
Similarly, the control unit 160 may calculate the tentative maximum instantaneous temperature tHT, using the 70th percentile stored as configuration parameter: if the calculate tentative minimum instantaneous temperature tHT is significantly higher than the high temperature threshold AHT (e.g., 350 ° C.), then the control unit 160 may decide that the vehicle is being driven in a motorway environment, for which the statistical distribution 520 applies. The control unit 160 may in this case take a low percentile, e.g. lower than the 45th, and preferably the 30th of the actual statistical distribution, and calculate the tentative maximum instantaneous temperature tHT. If the calculated tentative maximum instantaneous temperature tHT is higher than the high temperature threshold AHT, the control unit 160 sets the maximum instantaneous temperature tHT equal to the high temperature threshold AHT. If the calculated tentative maximum instantaneous temperature tHT falls within a temperature range defined by the high temperature threshold AHT and a maximum instantaneous temperature lower limit (e.g., 250° C.), the maximum instantaneous temperature tHT is set equal to the calculated tentative maximum instantaneous temperature tHT. If instead the calculated tentative maximum instantaneous temperature tHT is lower than the maximum instantaneous temperature lower limit (this may occur in case the actual statistical distribution is centered around a high temperature, such as 300°-350° C., but has an extended lower tail that corresponds to relatively low temperature values), the maximum instantaneous temperature tHT is set equal to said maximum instantaneous temperature lower limit.
In conclusion, the filter regeneration system according to the embodiments of the invention herein described allows to substantially improve the efficiency of the regeneration process of a DPF for a vehicle, both in terms of power consumption and reliability. Particularly, it has been found that, with the proposed solution, the heating device is activated only when the conditions for a successful filter regeneration are favorable. In this way, the occurrence of unnecessary activations of the heating device are reduced, so as to avoid excessive waste of electrical power.
Another advantage provided by the proposed solutions is that the filter regeneration system herein described needs very few additional hardware resources to be installed on the vehicle, being necessary only the addition of a filter regeneration apparatus including the temperature sensor after the DPF, an input lid structure provided with glow plugs directly contacting the DPF input base, and an electronic control unit (the pressure sensor being normally already mounted in all the vehicles including a particulate filter).
In view of the above, the proposed filter regeneration system may be advantageously installed in whichever vehicle type, without having to drastically modify the fabrication process of the vehicle itself.
Moreover, the condition on the average pressure PRm of the block 445 can be modified so as its value has to fall in a range defined by the minimum average pressure LPRm and a maximum average pressure HPRm (higher threshold), wherein said maximum average pressure HPRm may be set, for example, to the minimum alarm average pressure LAPRm. In this way, if the average pressure PRm exceeds said maximum average pressure HPRm, it means that the DPF 125 includes too much PM, and an emergency regeneration needs to be performed.
Even if in the present description reference has been made to a system for regenerating particulate filters that filter the PM emissions generated by a diesel engine, the concepts of the present invention can be applied to other types of engines, like the gasoline ones.
Naturally, in order to satisfy local and specific requirements, a person skilled in the art may apply to the solution described above many modifications and alterations. Particularly, although the present invention has been described with a certain degree of particularity with reference to preferred embodiment(s) thereof, it should be understood that various omissions, substitutions and changes in the form and details as well as other embodiments are possible; moreover, it is expressly intended that specific elements and/or method steps described in connection with any disclosed embodiment of the invention may be incorporated in any other embodiment as a general matter of design choice.
For example, the control unit may be adapted to vary, when in operation, the value of one or both of the percentiles used for setting the minimum and maximum instantaneous temperatures, so as to even better fit the expected driving condition of the vehicle 100 .
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A method for inducing the regeneration of a particulate filter associated with an exhaust gas emitting engine while being operated in a vehicle in variable driving conditions. The method includes turning on, for a time period, a heating device in physical contact with the filter subject to the following conditions: i) an average pressure of the exhaust gas at the entrance of the filter is greater than a predetermined value; and ii) an instantaneous pressure of the exhaust gas at the entrance of the filter is at a high improbable value. The time period for such heating device to stay turned on is sufficiently long to reach the particulate ignition temperature and for such instantaneous pressure to get from such high improbable value to a significantly lower value. The average pressure is obtained by averaging a plurality of pressure data sensed at the entrance of the filter.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a starting clutch mainly used in an automatic transmission of a vehicle and the like.
2. Related Background Art
FIG. 25 is an axial sectional view of a conventional starting clutch, showing an example of a conventional arrangement. A starting clutch 201 includes a wet type multi-plate clutch 203 and a damper 204 which are disposed within a case 210 . In the wet type multi-plate clutch 203 , friction plates 290 spline-fitted onto an outer periphery of a hub 280 and separator plates 300 spline-fitted into an inner periphery of a clutch case 310 are alternately arranged and dislodgment of these plates is prevented by a snap ring 212 disposed at an open end of the clutch case 310 .
On the other hand, a piston 230 for applying a load to the friction plates 290 and the separator plates 300 is also disposed at the open end of the clutch case 310 . The piston 230 is operated by supplying hydraulic oil into an oil chamber 250 defined between the piston and an inner wall of the clutch case 310 , and the hydraulic oil is supplied through oil passages 271 , 272 provided in members disposed at the inner peripheral side of the wet type multi-plate clutch 203 and oil passages 241 , 243 provided in a drive shaft 240 . Lubrication of the starting clutch is effected by an electrical pump or an engine pump mainly used for operating the piston.
While the operation of the piston of the wet type multi-plate clutch of the starting clutch has been effected by the hydraulic oil as mentioned above, in recent years, use of an electric motor or an electrically operated equipment such as a ball screw has been investigated in order to enhance accuracy of control of the operation of the piston. On the other hand, since it is not required that the hydraulic oil for operating the piston be supplied, it is considered that the electrical pump or the engine pump can be omitted, but, alternatively, it is required that means for supplying lubricating oil to the wet type multi-plate clutch be reserved.
SUMMARY OF THE INVENTION
Therefore, an object of the present invention is to eliminate an electric pump or an engine pump for operating a piston of a wet type multi-plate clutch and for supplying lubricating oil and to constitute a substitutive pump mechanism with a simple construction and to circulate the lubricating oil within a starting clutch.
To achieve the above object according to the present invention, there is provided a starting clutch in which lubricating oil supplied from a drive shaft side is circulated within the clutch and input side elements and output side elements are tightened or engaged by an axial load to transmit a power and wherein a non-electrically operated pump mechanism is provided within the starting clutch.
More specifically, the non-electrically operated pump mechanism is achieved by grooves or ports or vanes provided in or on at least one of rotary members constituting the starting clutch.
Although the pump mechanism can be achieved by the grooves, ports or vanes provided in or on at least one of the members constituting the starting clutch as mentioned above, in a preferred embodiment of the present invention, the grooves are formed in a drive shaft, a piston, a pawl member of a damper, a clutch case, friction plates and separator plates, and the ports are formed in a base member and the vanes are formed on the base member, a hub and a case. Many grooves, ports of vanes are provided in various areas in order to enhance a circulating ability. The grooves, ports or vanes are formed in spiral or helical forms or have inclination angles with respect to a radial, axial or circumferential direction. Further, the inclination angles, number and arranging sites of the grooves or the vanes can be appropriately selected in accordance with a concrete configuration of the starting clutch and/or required pump capacity. Further, selection of grooves, ports or vanes can be appropriately determined.
Further, the groves, ports or vanes having the pumping function can be obtaining by machining members constituting the starting clutch or by forming them integrally with such members. Alternatively, the grooves, ports or vanes may be formed in other members than the rotary members constituting the starting clutch and may be mounted to the rotary members. In a preferred embodiment, the former includes grooves formed in outer periphery of a drive shaft, ports formed in a base member, grooves formed in a piston, grooves formed in a pawl member of a damper, grooves formed in a clutch case, groves formed in friction plates and grooves formed in separator plates, and the latter includes grooves formed in inner periphery of the drive shaft, vanes formed on inner periphery of, the base member, vanes formed on a hub and vanes formed on the case.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an axial sectional view of a starting clutch according to an embodiment of the present invention;
FIG. 2 is an axial enlarged view showing main parts of the starting clutch of FIG. 1 ;
FIG. 3 is a front view of a first vane wheel according to an embodiment of the present invention;
FIG. 4 is an axial sectional view of the first vane wheel according to the embodiment;
FIG. 5 is a front view of a piston according to an embodiment of the present invention;
FIG. 6 is an axial sectional view of the piston according to the embodiment;
FIG. 7 is a front view of the drive shaft according to an embodiment of the present invention;
FIG. 8 is an axial sectional view of a cylindrical member according to an embodiment of the present invention;
FIG. 9 is a side view of the drive shaft, looked at from a direction shown by the arrow A in FIG. 7 ;
FIG. 10 is a sectional view of a second vane wheel, taken along the line 10 — 10 in FIG. 11 ;
FIG. 11 is a side view of the second vane wheel according to an embodiment of the present invention;
FIG. 12 is a front view of a base member according to an embodiment of the present invention;
FIG. 13 is an axial sectional view of the base member according to the embodiment;
FIG. 14 is a front view of a hub according to an embodiment of the present invention;
FIG. 15 is a side view of the hub according to the embodiment;
FIG. 16 is a front view of a friction plate according to an embodiment of the present invention;
FIG. 17 is an axial sectional view of the friction plate according to the embodiment;
FIG. 18 is a front view of a separator plate according to an embodiment of the present invention;
FIG. 19 is an axial sectional view of the separator plate according to the embodiment;
FIG. 20 is a front view of a clutch case according to an embodiment of the present invention;
FIG. 21 is a rear view of the clutch case according to the embodiment;
FIG. 22 is a side view of the clutch case according to the embodiment;
FIG. 23 is a front view of a pawl member according to an embodiment of the present invention;
FIG. 24 is an axial sectional view of the pawl member according to the embodiment; and
FIG. 25 is an axial sectional view of a conventional starting clutch.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will now be explained in connection with embodiments thereof with reference to the accompanying drawings. Incidentally, in the drawings, the same elements are designated by the same reference numerals. It should be noted that the embodiments that will be described hereinbelow are merely examples of the present invention and so not limit the present invention.
FIG. 1 is an axial sectional view showing an entire construction of a starting clutch according to an embodiment of the present invention. The starting clutch 1 includes a wet type multi-plate clutch 3 and a damper 4 which are disposed within a case 10 . In the wet type multi-plate clutch 3 , friction plates (friction engagement elements) 90 are spline-fitted onto a hub 80 and separator plates (friction engagement elements) 100 are spline-fitted into a clutch case 110 which is disposed coaxially with the hub, and dislodgment of these plates is prevented by a snap ring 12 disposed at an open end of the clutch case 110 .
A piston 30 is disposed at the open end of the clutch case 110 , and a loading spring 6 for applying an engaging load (tightening load) is disposed at an inner diameter side of the piston 30 . Further, a leaf spring 8 is disposed between the piston 30 and the separator plate 100 nearest to the piston to absorb or prevent shock during the engagement. Further, when a lever 2 is rotated in an anti-clockwise direction ( FIG. 1 ) by an operation of a ball screw (not shown) to urge a release bearing 55 and a base member 70 to the right in FIG. 1 , the piston 30 secured to the base member 70 is shifted to the right in opposition to the urging load of the loading spring 6 , thereby releasing the engagement load for the friction engagement elements. On the other hand, when the lever 2 is rotated in a clockwise direction ( FIG. 1 ) by the operation of the ball screw, the piston 30 is shifted to the left in FIG. 1 by the urging load of the loading spring 6 , thereby applying the engagement load to the friction engagement elements. In this case, the base member 70 and the release bearing 55 are returned to the left in FIG. 1 by the loading spring 6 .
The damper 4 is constituted by a retainer plate 7 secured to an inner wall of the case 10 , a damper spring 11 held by the retainer plate 7 , and a pawl member 120 secured to a side surface of the hub 80 and engaged by the damper spring 11 . With this arrangement, torque inputted from an engine is transmitted to the hub 80 through the case 10 , and vibration is absorbed by receiving the pawl member 120 secured to the hub 80 by means of the damper spring 11 . Incidentally, the torque is transmitted from the hub 80 to the clutch case 110 through the friction engagement elements and then is outputted to a crank shaft 40 spline-connected to an inner periphery of the clutch case 110 .
Supplying of lubricating oil to the friction engagement elements (friction plates 90 and separator plates 100 ) is effected by supplying lubricating oil from a tank (not shown) to a space between the hub 80 and the piston 30 through a gap between the crank shaft 40 and a fixed shaft 5 , a cavity 9 and an oil port 71 provided in a second vane wheel 60 and the base member 70 (i.e., effected through the oil port 71 from the inner diameter side of the hub 80 ). Thereafter, the lubricating oil is discharged toward an outer peripheral side through an oil port 118 of the clutch case 110 and reaches an inner diameter side of the drive shaft 40 through a space between the clutch case 110 and the case 10 and then is returned to the tank. Incidentally, flow of the lubricating oil is shown by the arrows in FIG. 1 .
FIG. 2 is an enlarged view showing main parts of the starting clutch, illustrating the inner diameter side of the hub 80 in an enlarged scale. The circulation of the lubricating oil is effected by rotations of a first vane wheel 20 provided at the inner diameter side portion of the hub 80 and grooves 34 provided in the inner diameter portion of the piston 30 . Further, the lubricating oil is supplied to the friction engagement elements through an oil port 84 provided in the hub 80 .
FIG. 3 is a front view of the first vane wheel 20 and FIG. 4 is an axial sectional view of the first vane wheel 20 . The first vane wheel 20 is made of synthetic resin and can be formed by injection molding and the like. The first vane wheel 20 is constituted by integrally arranging vanes 22 on an annular plate portion 21 . Each vane 22 is inclined in a radial direction so that, when the first vane wheel 20 is rotated in a clockwise direction in FIG. 3 , the lubricating oil flows from an inner peripheral side to an outer peripheral side. Incidentally, the annular plate portion 21 is provided with substantially semi-circular notches 23 , and the annular plate portion is secured to a recipient member by fitting the notches onto the recipient member and by effecting caulking. Incidentally, as shown in FIG. 1 , two first vane wheels 20 are provided within the hub 80 and within the case 10 .
FIG. 5 is a front view of the piston 30 and FIG. 6 is an axial sectional view of the piston 30 . Spiral grooves 34 are formed in an inner peripheral side of an urging surface 31 of the piston 30 and in an opposite surface 32 opposite to an arrangement portion 33 against which the loading spring 6 abuts. Each groove 34 has a predetermined inclination angle with respect to the radial direction so that, when the piston 30 is rotated in an anti-clockwise direction in FIG. 5 , the lubricating oil flows from the inner peripheral side to the outer peripheral side.
FIGS. 7 to 9 show the drive shaft 40 shown in FIG. 1 . FIG. 7 is a front view of the drive shaft 40 , FIG. 8 is an axial sectional view of a cylindrical member 50 , and FIG. 9 is a side view of the drive shaft 40 , looked at from a direction shown by the arrow in FIG. 7 . The drive shaft 40 is provided at its outer peripheral surface with splines 46 which can be fitted in the clutch case 110 , and a spiral or helical groove 44 having a predetermined angle with respect to an axial direction. Due to the presence of the groove 44 , when the drive shaft 40 is rotated in a clockwise direction looked at from the direction A, the lubricating oil existing at the outer peripheral side flows to the right in FIG. 7 .
On the other hand, as shown by the broken line in FIG. 7 , the drive shaft 40 is provided at its interior with an axially extending cavity 41 and an oil port 42 extending axially from the cavity 41 and having a diameter smaller than that of the cavity 41 . Further, there is provided an oil port 43 extending radially from a closed end portion of the oil port 42 and passing through a wall of the drive shaft. As apparent from FIG. 7 , the cavity 41 , oil port 42 and oil port 43 are communicated with each other.
The cylindrical member 50 shown in FIG. 8 is press-fitted into the cavity 41 from the direction A in FIG. 7 . The cylindrical member 50 is provided at its interior with an oil port 51 and a helical groove 52 inclined at a predetermined angle with respect to the axial direction is formed in an inner wall of the oil port 51 . Due to the presence of the groove 52 , when the drive shaft 40 is rotated in the clockwise direction looked at from the direction A, the lubricating oil existing in the oil port 51 flows to the left in FIG. 7 and is then discharged out of the drive shaft 40 through the oil ports 42 , 43 and is returned to the tank (not shown).
As can be seen from the side view of the drive shaft 40 shown in FIG. 9 , grooves 45 each having a pumping function are provided in a side surface of the drive shaft 40 . Similarly, grooves 53 are formed in a side surface of the cylindrical member 50 . The grooves 45 and the grooves 53 are radially extending grooves each having a predetermined angle with respect to the radial direction, and the grooves 45 are aligned with the grooves 53 to be continuously interconnected. That is to say, the groove 45 is communicated with the corresponding groove 53 to form an integral groove at a glance. In this case, when the oil port 43 is inclined with respect to the radial direction, the oil port can have a pumping function, and, in the illustrated embodiment, orientation of the inclination angle of the oil port is opposite to those of the grooves 45 , 53 shown in FIG. 9 .
As shown in FIG. 9 , a spline 46 comprised of mountain portions 46 a and valley portions 46 b is formed on the outer peripheral surface of the drive shaft 40 to be spline-connected to the clutch case 110 .
FIGS. 10 and 11 show the second vane wheel 60 in detail. FIG. 10 is a sectional view taken along the line 10 — 10 in FIG. 11 , and FIG. 11 is a side view of the second vane wheel 60 . The second vane wheel 60 has two annular side plates 62 between which vanes 61 are disposed in a condition that they are inclined with respect to the radial direction. When the vane wheel 60 is rotated in an anti-clockwise direction in FIG. 10 , the lubricating oil flows toward an outer diameter direction. Further, small projections 63 are formed on outer peripheral edges of the annular side plates 62 so that the vane wheel can be attached to the base member 70 (described later) by means of such small projections.
FIGS. 12 and 13 show the base member 70 in detail. FIG. 12 is a front view of the base member 70 and FIG. 13 is an axial sectional view of the base member. The base member 70 is provided at its outer periphery with an annular recess 75 and an annular extension 76 . The base member 70 is secured or fixed by arranging a seal member 78 (refer to FIG. 1 ) on a left (in FIG. 13 ) side surface 76 a of the extension 76 and fitting a snap ring into the recess 75 . On the other hand, the piston 30 is secured to a right (in FIG. 13 ) side surface 76 b of the extension 76 welding.
Further, the base member 70 has oil ports 71 passing through the base member from its inner periphery to its outer periphery, and opening portions 72 wider than the oil ports 71 are formed in the inner peripheral side. Each oil port 71 has a predetermined inclination angle with respect to the radial direction as shown by the broken line in FIG. 12 . When the base member 70 is rotated in an anti-clockwise direction in FIG. 12 , the lubricating oil flows from the inner peripheral side to the outer peripheral side. Incidentally, the second vane wheel 60 is fixed or secured by fitting the vane wheel into an annular recessed groove 73 formed in the inner peripheral surface of the base member 70 and by attaching a snap ring into an annular groove 74 .
FIGS. 14 and 15 show the hub 80 in detail. FIG. 14 is a front view of the hub 80 and FIG. 15 is a side view of the hub 80 . A spline is formed on an outer peripheral flange 81 of the hub 80 . The spline is constituted by mountain portions 81 a and valley portions 81 b . A plurality of oil ports 84 (shown in FIG. 2 as section) are formed in the valley portions 81 b of the spline along the spline. The spline has a predetermined inclination angle with respect to the axial direction so that, when the hub 80 is rotated in a clockwise direction in FIG. 14 , the lubricating oil is apt to be flown to the right in FIG. 1 or FIG. 15 .
However, since the inclination angle is selected to be so smaller that the inclination angle does not affect a bad influence upon the operation of the friction plates 90 and the separator plates 100 , such inclination angle gives an effect mainly at a low speed rotation area. Although not shown, each oil port 84 also has a predetermined inclination angle with respect to the radial direction so that, when the hub is rotated in a clockwise direction in FIG. 14 , the lubricating oil flows from the inner peripheral side to the outer peripheral side. Incidentally, the inclination is angled leftwardly from the inner peripheral side to the outer peripheral side. Further, an inner peripheral surface 82 of the hub is attached to an inner diameter side flange of the case 10 and is secured by a snap ring. Further, the pawl member 120 which will be described later is secured to a rear surface 83 of the hub 80 by welding.
FIGS. 16 and 17 show the friction plate 90 used in the embodiment of the present invention in detail. FIG. 16 is a front view of the friction plate 90 and FIG. 17 is an axial sectional view of the friction plate. The friction plate 90 is constituted by adhering a friction material 92 on an annular core plate 91 having a spline at its inner peripheral edge. The spline includes mountain portions 94 a and valley portions 94 b . Grooves 93 each an inclination angle with respect to the radial direction are formed in the friction material 92 .
When the friction plate 90 is rotated in an anti-clockwise direction in FIG. 16 , the lubricating oil flows from the inner diameter side to the outer diameter side. By supplying the lubricating oil to the friction materials 92 , the friction plates and the separator plates (described later) are cooled. Incidentally, the grooves 93 can be obtained by urging or cutting the friction material or can be obtained by adhering a plurality of friction material segments with a predetermined gap therebetween. According to the grooves formed by the combination of the segments, since the depth of the groove can be increased, the greater pumping action can be achieved.
FIGS. 18 and 19 show the separator plate 100 in detail. FIG. 18 is a front view of the separator plate 100 and FIG. 19 is an axial sectional view of the separator plate. In FIG. 1 , the separator plate 100 is disposed in adjacent to the snap ring 12 . Further, each separator plate 100 is provided at its outer peripheral edge with a spline fitted into the inner periphery of the clutch case 110 . The spline includes mountain portions 102 a and valley portions 102 b . Further, grooves 103 communicating between the outer periphery and the inner periphery and each having a predetermined inclination angle with respect to the radial direction are formed in a surface 102 which is not contracted with the friction plate 90 . When the separator plate 100 is rotated in an anti-clockwise direction in FIG. 18 , the lubricating oil flows from the inner diameter side to the outer diameter side.
FIGS. 20 to 22 show the clutch case 110 in detail. FIG. 20 is a front view of the clutch case 110 , FIG. 21 is a rear view of the clutch case and FIG. 22 is a side view of the clutch case. As shown in FIG. 20 , the clutch case 110 has inner wall surfaces 118 a , 118 b , 118 c extending radially, and grooves 111 a and 111 b each having a predetermined inclination angle with respect to the radial direction are formed in the inner walls 118 a 118 b , respectively, and projections 113 for supporting the loading spring 6 are formed on the inner wall 118 c.
Further, mountain portions 114 a and valley portions 114 b of a spline to be fitted onto the separator plates 100 are formed an axially extending portion at the outer diameter side, and the spline also has a predetermined inclination angle with respect to the axial direction (refer to FIG. 22 ). On the other hand, as shown in FIG. 22 , grooves 115 a , 115 b , 115 c each having a predetermined inclination angle with respect to the radial direction are formed in outer wall surfaces 117 a , 117 b , 117 c extending radially outside of the clutch case 110 . Further, as shown in FIG. 22 , there are provided a plurality of oil ports 119 passing through the clutch case 110 from the inner periphery to the outer periphery. Although not shown, each oil port 119 also has a predetermined inclination angle with respect to the radial direction so that, when the clutch case 110 is rotated in an anti-clockwise direction in FIG. 20 , the lubricating oil flows form the inner peripheral side to the outer peripheral side.
Incidentally, the inclination angle is inclined to the right from the inner peripheral side to the outer peripheral side. With this arrangement, when the clutch case 110 is rotated in the anti-clockwise direction in FIG. 20 , the lubricating oil is supplied more positively toward the outer peripheral side of the clutch case 110 by a centrifugal force and the pumping action of the grooves 111 a , 111 b and the oil ports 119 and then is routed to the rear side of the clutch case 110 by the pumping action of the spline having the inclination angle and then is sucked toward the inner peripheral side by the pumping action of the grooves 115 a , 115 b , 115 c.
FIGS. 23 and 24 show the pawl member 120 of the damper in detail. FIG. 23 is a front view of the pawl member 120 and FIG. 24 is an axial sectional view of the pawl member. As shown in FIG. 1 , the pawl member 120 is provided at its outer periphery with a fitting portion 122 engaged by the damper spring 11 . Further, grooves 124 , 125 each having a predetermined inclination angle with respect to the radial direction are formed in a radially extending bottom surface 121 . Further, grooves 126 each having a predetermined inclination angle with respect to the axial direction are formed in an inner peripheral surface 127 . When the pawl member 120 is rotated in an anti-clockwise direction in FIG. 23 , the lubricating oil is supplied toward the inner peripheral surface 127 by a centrifugal force and the pumping action of the grooves 124 , 125 and is flown to the left in FIG. 24 by the pumping action of the grooves 126 .
Although the present invention can be carried out in accordance with the above-mentioned embodiment, the present invention is not particularly limited to such an embodiment. For example, at least one of the vanes 22 , 61 of the first vane wheel 20 and the second vane wheel 60 , and at least one of the groves formed in various members may be used, but, all of the vanes and the grooves may not always be used. Further, the number and the inclination angles of the vanes 22 , 61 and/or grooves of the members can be selected appropriately. Further, while the plural oil ports 84 , 119 were illustrated in the drawings, single oil port may be used.
As mentioned above, according to the starting clutch of the present invention, the following effect can be achieved.
An electrical pump or an engine pump for effecting the operation of the starting clutch and the supplying of the lubricating oil can be eliminated, and a substitutive pump mechanism can be obtained with a simple construction to circulate the lubricating oil within the starting clutch.
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In the starting clutch, an electrical pump or an engine pump is omitted and a substitutive pump mechanism is obtained with a simple construction thereby to circulate lubricating oil within the starting clutch. There is provided a starting clutch in which lubricating oil supplied form a drive shaft side is circulated within the clutch and input side elements and output side elements are tightened by an axial load to transmit a power and wherein a non-electrically operated pump mechanism is provided within the starting clutch.
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FIELD OF THE INVENTION
[0001] The present disclosure relates to drawing materials, and more particular, to a writing and drawing substrate in book form, with erasable pages.
BACKGROUND OF THE INVENTION
[0002] From time to time, it is desirable to provide small children with ways to amuse themselves. One of the ways is to provide a reusable writing surface capable of receiving markings thereon, being erased, and subsequently reused. It would further be desirable to have the writing surface in the form of a book, to promote positive feelings towards books by small children.
[0003] Reusable, erasable writing surfaces and books have been proposed. However, many of these do not address aspects of use which are encountered by small children, but not by older children and adults.
[0004] There remains a need for an erasable marking book particularly suited to the needs of small children.
SUMMARY
[0005] The disclosed concepts address the above stated situation by providing a markable, erasable book having characteristics suited for use by small children. To this end, the novel drawing book disclosed herein has mildly flexible polymeric pages which are liquid resistant and which will yield if for example a child sits on a page when seated on an upholstered or cushioned surface. The exterior of the drawing book may have a woven, rubbery surface so it will not readily slip from a child's grasp, and to impart a unique tactile identity to facilitate the drawing book being retrieved by a caregiver from bags and other receptacles storing accessories and materials unrelated to the drawing book, and to reassure the child that he or she has grasped the drawing book and not some other object.
[0006] The drawing book may have rounded corners, with corners of interior pages recessed within the bounds of the covers of the drawing book, to minimize the likelihood of the child poking himself or herself with sharp corners. Also, over time and with repeated use, the pages may become misaligned with the covers. If not recessed within the bounds of the covers, some pages could come to stick out objectionably. Further, recessed pages are more easily located and turned by small children, who might otherwise grasp a cover rather than the desired page.
[0007] The drawing book may have fabric borders greater in thickness than the marking receiving portion of the page to provide small children with a sense of where the boundary of each page is located. Also, liquid markers and inks and chalk can leave residues which bleed, or migrate beyond the page. A relatively thick fabric border intercepts these migrating materials and helps prevent fouling the child's clothing and other environmental surfaces. Thickened borders also reinforce pages, for example by opposing folding of corners and fraying of page edges over time and with use. Also, thickened borders help very young children learn motor skills related to turning the pages.
[0008] The drawing book may include an interior spine which promotes spreading apart of pages, thereby causing the book to lie flat when placed on a horizontal surface.
[0009] Interior pages are made from a liquid resistant polymeric material textured to abrade a writing material such as chalk and grease pencil, and to retain abraded writing material so that indicia remains visible until erased.
[0010] The nature of the disclosed concepts will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Various objects, features, and attendant advantages of the disclosed concepts will become more fully appreciated as the same becomes better understood when considered in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the several views, and wherein:
[0012] FIG. 1 is a schematic perspective side view of an erasable writing book, according to at least one aspect of the disclosure;
[0013] FIG. 2 is a schematic perspective view of an erasable writing book, shown with pages spread open to reveal internal detail, according to at least another aspect of the disclosure;
[0014] FIG. 3 is a schematic detail side view of the interior of a rear cover of an erasable writing book, according to at least one further aspect of the disclosure;
[0015] FIG. 4 is a schematic perspective view of an optional feature of an erasable writing book; and
[0016] FIG. 5 is a schematic side detail view taken from the center of FIG. 4 .
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0017] Referring first to FIGS. 1 and 2 , according to at least one aspect of the disclosure, there is shown an erasable writing book 100 for erasably accepting indicia from writing materials such as chalk and grease pencils (neither shown). Erasable writing book 100 comprises a front cover 102 , a rear cover 104 , at least one interior page 106 , and at least one interior spine 108 . Front cover 102 comprises an interior face 110 bearing a flexible, liquid resistant polymeric substance including texturing thereon for abrading the writing materials and retaining abraded writing materials thereon. The at least one interior page 106 comprises opposed front and rear faces 112 , 114 each bearing a flexible, liquid resistant polymeric substance including texturing thereon for abrading writing materials such as chalk and grease pencils and retaining abraded writing materials thereon. Rear cover 104 comprises an interior face 116 bearing a flexible, liquid resistant polymeric substance including texturing thereon for abrading writing materials such as chalk and grease pencils and retaining abraded writing materials thereon. One interior spine 108 overlies two adjacent ones of edges 118 , 120 of two respective interior pages 106 and an edge 118 or 120 of interior page 106 , one of an edge 122 of interior face 110 of front cover 102 , and interior face 116 of rear cover 104 . Interior spine 108 exerts a force spreading apart interior pages 106 or spreading apart interior page 106 and interior face 110 (or 116 ) of front cover 102 (or of rear cover 104 ), whereby manual effort to maintain erasable writing book 100 flat is minimized.
[0018] Writing materials may include liquid inks (not shown) as well as chalk and grease pencils. In some embodiments (not shown), interior spine 108 may be supplemented by other interior spines (not shown) between other interior pages 106 , between interior face 110 of front cover 102 and an interior page 106 , or between an interior page 106 and interior face 116 of rear cover 104 .
[0019] The flexible, liquid resistant polymeric substance may be any suitable polymeric material heat treated or molded to include texturing thereon for abrading and retaining writing materials thereon. Texturing may be of characteristics of a dried coat of wrinkle paint, for example. Flexibility is sufficient to squirm under the weight of a child sitting on an open page while seated on an upholstered or cushioned chair, but not to enable a page to slump spontaneously if held by an edge for example.
[0020] In embodiments wherein erasable writing book 100 comprises at least two interior pages 106 , interior spine 108 may extend along the full length of the two adjacent edges 118 , 120 of two respective interior pages 106 . This arrangement reinforces connection of interior pages 106 , which would otherwise be susceptible to eventual damage after long usage by youngsters.
[0021] Each interior page 106 may comprise a fabric-like border 122 thicker than the rest of interior page 106 . Fabric-like border 122 may be of woven fabric, unwoven fabric, or of stitching. Fabric-like border 122 is liquid permeable. This construction and thickness intercept and retain excessive liquid ink deposited by a marker (not shown) being used to mark erasable writing book 100 , and will to a degree intercept and retail chalk dust. Fabric-like border 122 may extend along the entire border of each interior page 106 . This reinforces each interior page 106 for long term usage by small children, and accommodates tactile recognition of the borders of each interior page 106 .
[0022] Each interior page 106 may comprise rounded corners 124 . Also, front cover 102 may comprise rounded corners 126 , and rear cover 104 may comprise rounded corners 128 . Rounded corners 124 , 126 , 128 avoid injuries which could arise from conventional square or sharp corners. Front cover 102 and rear cover 104 comprise a height dimension 130 , and each interior page 106 may comprise a height dimension 132 less than height dimension 130 of front cover 102 and rear cover 104 . Interior pages 106 are thereby protectively recessed within front and rear covers 102 , 104 , and will last longer in the hands of small children, especially should the binding (not shown) lose grip of interior pages 106 . Also, it will be easier for very small children to grasp interior pages 106 . Without interior pages 106 being recessed, a very small child might be more likely to grasp front cover 102 or rear cover 104 .
[0023] Front cover 102 may include an exterior face 134 bearing rubberized fabric. Rear cover 104 may include an exterior face 136 bearing rubberized fabric. Woven rubberized fabric resists slipping from a child's hand. Also, woven rubberized fabric imparts tactile identity to facilitate identifying erasable writing book 100 should it be underneath furniture or be retrieved from a bag, suitcase, or other receptacle where it is buried under or surrounded by other objects. The tactile identity also assists children in identifying erasable writing book 100 by touch, thereby promoting tactile development.
[0024] Referring also to FIG. 3 , erasable writing book 100 may further comprise a pocket 138 coupled thereto, for storing writing apparatus (such as chalk and grease pencils, not shown). Pocket 138 may comprise an open end 140 for receiving objects (none shown) inserted thereinto and a closed end 142 coupled to erasable writing book 100 .
[0025] Front cover 102 may comprise a fabric-like border 144 and rear cover 104 may comprise a fabric-like border 146 . Erasable writing book 100 may further comprise pocket 138 coupled to fabric-like border 144 or 146 of (respectively) front cover 102 or of rear cover 104 . Pocket 138 has open end 140 for receiving objects (not shown) inserted thereinto and closed end 142 coupled to fabric-like border 144 or 146 . This arrangement conveniently anchors pocket 138 on erasable writing book 100 .
[0026] Closed end 142 of pocket 138 may be long enough to be folded over against itself with open end 140 thereof entrapped between closed end 142 and either front cover 102 or rear cover 104 . Open end 140 may be covered by closed end 142 such that the objects inserted into pocket 138 are prevented from inadvertent loss by interference with closed end 142 . Length of pocket 138 enables pocket 138 to be folded as shown in FIG. 2 .
[0027] As seen in FIG. 3 , pocket 138 may be divided into two compartments 148 each accessible through open end 140 . This enables different objects to be segregated from each other. For example, writing materials may be segregated by color or type. Other objects such as keys, coins, and the like may be segregated from writing materials.
[0028] Erasable writing book 100 may further comprise a flexible closure tab 152 coupled to one of front cover 102 and rear cover 104 , and a complementing attachment element 154 at the other one of front cover 102 and rear cover 104 . In the embodiment depicted in FIG. 1 , flexible closure tab 152 bears hook and loop fastening material 156 of one polarity, while complementing attachment element 154 bears hook and loop fastening material 158 of an opposite polarity. Flexible closure tab 152 enables erasable writing book 100 to be carried about compactly, while protecting front cover 102 , interior pages 106 , and rear cover 104 from inadvertent damage.
[0029] Interior face 110 of front cover 102 , interior face 116 of rear cover 104 , and opposed front and rear faces 112 , 114 (respectively) of each interior page 106 may be of an intermediate color between the lightest possible rendering of the color and the darkest possible rendering of the color. Considering the example of white, grays, and black, with white being the lightest possible rendering and black being the darkest possible rendering, the intermediate color may be gray. The same principle may be applied to chromatic colors.
[0030] In one embodiment of erasable writing book 100 , front cover 102 may comprise exterior face 134 including texturing to increase frictional characteristics. Rear cover 104 may comprise exterior face 136 including texturing to increase frictional characteristics. Erasable writing book 100 is easily grasped by a small child in the above embodiment.
[0031] With particular reference to FIG. 4 , in an embodiment of erasable writing book 100 , one of front cover 102 or rear cover 104 may comprise exterior face 134 or 136 (respectively) bearing a storage compartment 160 , for storing articles greater in size than those which could fit into pocket 138 . Storage compartment 160 may be collapsible, to assume compact configuration when not in use. This may be achieved by fabricating storage compartment 160 as having pleated walls 162 , which are manually compressible to collapse storage compartment 160 when no articles are to be stored therein. Where storage compartment 160 is collapsible, storage compartment 160 may include structure making it relatively rigid. For example, and referring also to FIG. 5 , storage compartment 160 of claim 19 , may further comprise bracing selectively enabling storage compartment 160 to be maintained in a distended condition. I In the example of FIG. 5 , bracing comprises a first rigid panel 164 and a second rigid panel 166 . Second rigid panel 166 is coupled to front cover 102 by a hinge 168 enabling second rigid panel 166 to pivot relative to front cover 102 . Second rigid panel 166 may be manipulated to occupy a groove 170 in first rigid panel 164 to maintain storage 160 in the distended condition shown in FIG. 4 . When it is desired to collapse storage compartment 160 , second rigid panel 166 may be manipulated out of engagement with groove 170 .
[0032] Unless otherwise indicated, the terms “first”, “second”, etc., are used herein merely as labels, and are not intended to impose ordinal, positional, or hierarchical requirements on the times to which these terms refer. Moreover, reference to, e.g., a “second” item does not either require or preclude the existence of, e.g., a “first” or lower-numbered item, and/or, e.g., a “third” or higher-numbered item.
[0033] While the present invention comprises been described in connection with what are considered the most practical exemplary embodiments, it is to be understood that the present embodiments are not to be limited to the disclosed arrangements, but rather the description is intended to cover various arrangements which are included within the spirit and scope of the broadest possible interpretation of the appended claims so as to encompass all modifications and equivalent arrangements which are possible.
[0034] It should be understood that the various examples of the apparatus(es) disclosed herein may include any of the components, features, and functionalities of any of the other examples of the apparatus(es) disclosed herein in any feasible combination, and all of such possibilities are intended to be within the spirit and scope of the present disclosure. Many modifications of examples set forth herein will come to mind to one skilled in the art to which the present disclosure pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings.
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An erasable, polymeric paged writing book for small children, with textured, flexible, bordered pages and an internal spine to spread the book flat. The pages have rounded corners. The book closes by hook-and-loop tab. The pages have a smaller profile than the covers, for resistance to wear and distortion. A fold-away pocket holds chalk and grease pencils. Optionally, a pleated storage compartment is on one of the covers. The pages have a smaller profile than the covers, for resistance to wear and distortion.
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This application is a 371 of Pct/Fr98/01204 filed on Jun. 11, 1998.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to stable liposomal vectors, in pulverulent form, for active principles, and more particularly for active principles which are sensitive to digestive and/or plasmatic degradation, such as proteins, and to their use as medicinal products.
2. Description of the Background
Many vectors have been proposed to protect such fragile active principles; among these, mention should be made of liposomes, which have been considered as a vector of choice.
The first studies on the oral administration of liposomes were not conclusive (Deshmukh D. S. et al., Life Sciences, 1981, 28, 239-242). The results obtained showed that liposomes with the formulation: diether-phosphatidylcholine (indigestible PC analogues)/cholesterol-7:1 allowed gastrointestinal protection of the encapsulated peptide, but did not allow its passage across the intestinal barrier.
Several reasons may be put forward to explain this absence of passage: excessively large and non-calibrated size of the liposomes, low stability of the structure or leakage of the encapsulated compound into the extra-liposomal medium.
Recently, the research team of Robert Greenwood ( Drug Dev. and Ind. Pharm., 1993, 19, 11, 1303-1315) at the Campbell University, U.S.A., has succeeded in showing that the duodenal intubation of liposomes vectorizing insulin brought about a higher hypoglycaemiant effect than that obtained after a duodenal intubation of a solution of free insulin.
Many tests have been carried out to obtain liposomes with good capacity to transport active principles, in particular as regards the action on the percentage of uptake of the active principle, the stability of the liposomes and the bioavailability of the active principle. Mention may be made, for example, as a guide, of:
S. B. Kulkarni et al. ( J. Microencapsulation, 1995, 12, 3, 229-246) who point out the factors involved in the microencapsulation of medicinal products in liposomes: size of the liposome, type of liposome, surface charge of the liposome, rigidity of the bilayer, addition of encapsulation adjuvants. It emerges from this evaluation that MLVs (multilamellar vesicles) containing several bilayers and with a diameter of between 100 nm and 20 mm are desirable for the encapsulation of hydrophobic medicinal products interacting with the bilayers, whereas LUVs (large unilamellar vesicles) containing a single bilayer and with a size of between 100 and 1000 nm are considered as being the most suitable for the encapsulation of hydrophilic medicinal products.
I. De Miguel et al., (Biochimica et Biophysica Acta, 1995, 1237, 49-48 [sic]), who propose nanoparticles composed of an internal core formed from crosslinked polysaccharides grafted on their exterior with fatty acids and surrounded by a layer of phospholipids;
P. S. Uster et al., ( FEBS Letters, 1996, 386, 243-246) who propose the insertion of phospholipids modified with a poly(ethylene glycol) in preformed liposomes to improve the bioavailability.
Series of experiments relating to the oral administration of peptides have been carried out and use either different liposomal methods of encapsulation, or modification of the lipidic active principle by grafting lipophilic functions. In all cases, the aim is to convert the lipidic active principle into a “prodrug”; this prodrug has the property of withstanding gastrointestinal transit, i.e. resistance to gastric pH, to physiological detergents (bile salts), to proteases (intestinal exopeptidases and endopeptidases) and to metabolization by the intestinal flora. For example, the bridging in position 2 of a 1,3-diglyceride onto a pentapeptide made it possible to impart these qualities to the drug thus modified.
However, these various liposomes of the prior art do not make it possible to obtain both good stability, an acceptable active-principle encapsulation yield and a significantly improved oral bioavailability of the said active principle, without modifying the active principle, which thus conserves all of its functions and properties. The term “bioavailability” means the fraction of the dose which reaches the systemic circulation in pharmacologically active form and the rate at which it does so.
J. C. Hauton has described liposomes with a gelatinized internal core (lipogelosomes®) which are in suspension in aqueous medium containing gelatinizing substances. He has, in particular, developed a process for manufacturing such liposomes (European patent 0 393 049), which differ from conventional liposomes in that the encapsulated aqueous phase is in semi-solid gel form rather than in liquid form, and this prevents the liposomes from fusing during collisions. Such lipogelosomes® are produced entirely from natural substances, thereby minimizing the risk of intolerance. In particular, in European patent 0 393 049, these lipogelosomes® consist of one bilayer interfacial phase, in the case of the unilamellar lipogelosomes, or of a plurality of bilayer interfacial phases, which are superimposed concentrically, in the case of the multilamellar lipogelosomes®, and of a gelatinized encapsulated internal aqueous polar phase in which the gelatinized substance, which may or may not be polymerizable, is selected from polysaccharides, polypeptides or polyacrylamides; for example, the non-polymerizable gelatinizable substance is selected from gelatin, agarose or carrageenans, and the polymerizable gelatinizable substance is selected from polyacrylamide gels. These lipogelosomes® possess a stability which is significantly increased as compared with the liposomes of the prior art, particularly because of the absence of interparticulate fusion during collisions.
However, they suffer from the drawback of being in the form of a dispersion of liposomes in liquid phase, which is not suitable for preparing solid formulations which are easy to store and to administer.
SUMMARY OF THE INVENTION
Consequently, the Applicant set itself the objective of providing a novel vector which effectively makes it possible to obtain both a sufficient encapsulation yield and significantly improved oral bioavailability of the said active principle, compared with the liposomes of the prior art, while at the same time displaying great stability both on storage and in vivo. Said vectors are suited to oral administration; the aqueous solution is also suitable for other routes of administration: transdermal, pulmonary, nasal, genital, intravenous, subcutaneous or ocular, for example, depending on the excipient selected.
The said vectors are characterized in that they consist of:
a pulverulent composition which consists essentially of unilamellar liposomes comprising an external lipid phase which consists of class 4 lipids (phospholipids), optionally combined with class 2 substances (long-chain triglycerides, cholesterol esters), class 3 substances (cholesterol, nonionized long-chain fatty acids) and/or class 5 substances (bile salts, fusidic acid derivatives) and an internal aqueous core forming a temperature-reversible aqueous gel which radiates out up to the external lipid phase, which internal aqueous core essentially consists of a mixture M of at least two different non-polymerizable gelatinizing agents G1 and G2 whose gel-sol phase transition point is higher than or equal to 37° C., with G1 being a gelatinizing agent which is selected from gelatins and carrageenans, such as kappa-carrageenans, and G2 being selected from carrageenans whose properties are different from the carrageenans selected for G1, such as iota-carrageenans, and celluloses, such as hydroxypropylmethylcellulose, which liposomes have a diameter of between 20 nm and 1 mm, preferably of between 20 nm and 500 nm and being in the form of particulate units with an average diameter of between 10 mm and 1000 mm, formed from one or more of the said liposomes, surrounded by a matrix selected from the group consisting of a dehydrated temperature-reversible aqueous gel which is identical to the aqueous gel of the said internal core, dextrins or a mixture thereof, such that it comprises, on average, 10 16 to 10 18 liposomes/g of powder, and
at least one active principle included, depending on the case, either in the gelatinized internal core or in the external lipid phase of the said composition.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Surprisingly, such vectors make it possible to overcome the drawbacks associated with conventional liposomes. Specifically, they make it possible:
to increase the stability of the liposomes, on account of the absence of interparticulate fusion during collisions;
to increase the bioavailability of the active principle (protection in the gastrointestinal tract and passage across the intestinal barrier); in particular, in rats, the passage time of the vectors according to the invention (LGS) across the intestinal barrier from the moment of their oral administration can be between 2 and 4 hours: i.e. 1 hour of gastric emptying and 1 to 3 hours of passage from the intestinal lumen into the systemic circulation; thus, an active principle whose cellular internalization capacity is low or non-existent can be incorporated effectively into a differentiated intestinal epithelial cell, when it is encapsulated in a vector (LGS) according to the invention, without modifying the activity or composition of the active principle;
to reduce the toxicity of the the encapsulated active principles; and
to result in fewer leakages of the encapsulated products, on account of the lower molecular mobility in the gelatinized encapsulated aqueous phase.
Unexpectedly, by selecting the gelatinizing agents, it is possible to obtain liposomes (SUVs or small unilamellar vesicles), which are suitable for use in a dry form (powder) and which have particularly advantageous properties as vectors for active principles; in specific terms, surprisingly, the oral bioavailability of the said active principles—preferably of active principles which are sensitive to digestive degradation, poorly absorbed or highly toxic—is significantly increased when they are encapsulated or combined with the vector according to the present invention.
In addition, such vectors in pulverulent form conserve all the integrity of the liposomes they contain, which remain stable over time, both in pulverulent form and when they are suspended, on account of the maintenance of the integrity of the constituent lipids (no degradation product) and the maintenance of the integrity of the characteristics of the gelatinizing agents, in particular of the mixture G1 and G2 (viscosity, gel strength and breaking force, molecular masses).
The advantage of using lipogelosomes® (LGS) in this context is that of benefiting from a stabilized liposomal form (J C Hauton et al., Eur. J. Surg., 1994, suppl. 574, 117-119) for the purpose of the oral administration of active principles. The method for manufacturing LGSs makes it possible to obtain, on average, degrees of encapsulation of the gelatinized hydrophilic phases of close to 10%. This percentage varies, in particular as a function of the molecular weight of the active principle, and is calculated according to the ratio: amount of active principle encapsulated/amount of active principle used. For example, at least 5% encapsulation is observed for a 500 Da molecule and at least 50% encapsulation is observed for a molecule of at least 20 kDa. As regards peptides, for example, 10 to 50% encapsulation is observed, whereas, in general, for active principles as a whole, the percentage of encapsulation ranges from 5 to 80%, depending on the case.
The gelatinizing agents G1 and G2 differ in particular as regards the viscosity, molecular mass and gel-sol transition point (i.e. the melting point). For the gelatinizing agents C1, this temperature is less than or equal to 45° C., whereas it is greater than or equal to 45° C. for the gelatinizing agents G2.
The mixture M of at least two gelatinizing agents G1 and G2 as defined above has texturometric characteristics (gel strength and breaking force) which are particularly advantageous from the point of view of the stability of the liposomes obtained and the bio-availability of the encapsulated active principle. Thus, the mixture M of at least two gelatinizing agents G1 and G2 preferably has, at 5° C., relaxation characteristics of between 70 and 100%, preferably 81-89% and a breaking force of between 1000 and 1600 g, preferably 1109-1503 g.
According to another advantageous embodiment of the said composition, the said internal aqueous core of the liposomes also comprises at least one stabilizer of glycosidic nature, and/or at least one agent for regulating the osmolarity of the medium and/or at least one surfactant, such as a bile salt and/or a nonionic surfactant.
Advantageously, the said vectors comprise, as % (m/m): 25 to 75% of class 4 lipids, 5 to 45% of gelatinizing agents, 0 to 70% of stabilizer of glycosidic nature, 0 to 15% of agent for regulating the osmolarity of the medium, 0 to 20% of surfactants and 0 to 15% of dextrins, preferably 8 to 12%; this formulation does not include the active principles.
According to another advantageous embodiment of the said pulverulent composition according to the invention, the said aqueous internal core comprises 70 to 95% of gelatinizing agent G1 and 5 to 30% of gelatinizing agent G2.
According to another advantageous embodiment of the said pulverulent composition according to the invention, the stabilizer of glycosidic nature is sucrose, trehalose or any other protective agent.
The subject of the present invention is also a process for preparing the pulverulent vectors according to the invention, in which the external matrix of the particulate units comprises a fraction of temperature-reversible aqueous gel, characterized in that it comprises the following steps:
(1) preparation of a dispersion of liposomes with a gelatinized internal core (lipogelosomes®) in aqueous phase by (a) preparing a solution of at least one suitable gelatinizing agent, in particular a mixture M of gelatinizing agents G1 and G2, by dissolving the said gelatinizing agents, with slow stirring, at a temperature above the gel-sol phase transition temperature of the said gelatinizing agents, in an aqueous solution whose pH is compatible with the active principle to be encapsulated, (b) incorporating the active principle into the solution obtained in (a), (c) incorporating the lipids into the solution obtained in (b), with slow stirring of the mixture, for a period of less than 5 hours, preferably under vacuum, and formation of an emulsion, and (d) obtaining the said dispersion of liposomes with a gelatinized internal core (lipogelosomes®) in an aqueous phase containing the said gelatinizing agents, by rapid stirring of the emulsion obtained in (c), preferably under vacuum, and
(2) production of the pulverulent product by suitable drying of the dispersion obtained.
According to one advantageous embodiment of the said process, the drying is carried out by atomization, coacervation, thin layer or granulation.
Another subject of the present invention is a process for preparing the pulverulent vectors according to the invention, in which the external matrix of the particulate units comprises a fraction of temperature-reversible aqueous gel and/or a dextrin, characterized in that it comprises the following steps:
(1) preparation of a dispersion of liposomes with a gelatinized internal core (lipogelosomes®) in aqueous phase by (a) preparing a solution of at least one suitable gelatinizing agent, in particular a mixture M of gelatinizing agents G1 and G2, by dissolving the said gelatinizing agents, with gentle stirring, at a temperature above the gel-sol phase transition temperature of the said gelatinizing agents, in an aqueous solution whose pH is compatible with the active principle to be encapsulated, (b) incorporating the active principle into the solution obtained in (a), (c) incorporating the lipids into the solution obtained in (b), with slow stirring of the mixture, for a period of less than 5 hours, preferably under vacuum, and formation of an emulsion, and (d) obtaining the said dispersion of liposomes with a gelatinized internal core (lipogelosomes®) in an aqueous external phase containing the said gelatinizing agents, by rapid stirring of the emulsion obtained in (c), preferably under vacuum, and
(2) at least partial removal of the aqueous liquid phase containing the said gelatinizing agents, in which the liposomes are dispersed,
(3) addition of at least one suitable dextrin, and
(4) production of the pulverulent product by drying by atomization of the product obtained in (3).
According to one advantageous embodiment of the said process, step (2) of at least partially removing the aqueous liquid phase containing the said gelatinizing agents is carried out by dilution and/or filtration.
In accordance with the preparation processes according to the invention, the aqueous solution in step (a) also comprises an agent for regulating the osmolarity of the medium (for example 0.9% NaCl) and/or a stabilizer of glycosidic nature and/or a surfactant, preferably class 5 substances (bile salts).
As a variant, the active principle is added to the external lipid phase before it is incorporated into the mixture obtained in (a).
For example, calcitonin is incorporated at pH 5, AZT is incorporated at pH 7.5 and doxorubicin is incorporated at pH 3.
Surprisingly, such processes make it possible to obtain a vector in pulverulent form based on stable liposomes with a gelatinized internal core (lipogelosomes®) in the course of a single step comprising a phase of maturation (in the sense of ripening) of the constituents in aqueous phase, at slow speed, followed by a phase of dispersion (formation of the lipogelosomes®) at high speed, comprise a step during which a stable dispersion of lipogelosomes® in liquid phase, of homogeneous morphology, is obtained, which can be subjected to the drying step; such a dispersion of liposomes with a gelatinized internal core effectively has the following morphology:
vesicular structure with a diameter of between 20 nm and 500 nm, preferably between 20 and 80 nm,
negative staining microscopic observations, cryofracture, cryotransmission and atomic force: vesicles or assemblies of vesicles with the characteristic appearance of phospholipid bilayers; negative staining makes it possible to observe the more or less pronounced presence of a mixture M of gelatinizing agents enveloping the external phospholipid layer, and
polydispersity of the liposomes with a gelatinized internal phase of between 10 and 55%, preferably between 10 and 30%.
Such a process has the advantage of being reproducible and fully adaptable to the industrial scale.
It also has the advantage of being less cumbersome to implement than the processes of the prior art in which a step of sonication, extrusion or removal of detergents is necessary, as described in patent 0 393 049.
According to one advantageous embodiment of the said processes, the step (c) is preferably carried out at a shear rate of less than 200 s −1 ; in general, the shear rate is given by the following ratio: speed of the stirring unit/space between the internal wall of the reactor and the distal end of the stirring blade (also known as the “air gap”).
Another subject of the present invention is a pharmaceutical composition, characterized in that it comprises a pulverulent liposomal active-principle vector as defined above and at least one pharmaceutically acceptable vehicle.
According to one advantageous embodiment of the said composition, it is in solid form (gel capsule, tablet or powder to be dissolved in water).
According to another embodiment of the said composition, it also comprises a cAMP activator.
BRIEF DESCRIPTION OF THE DRAWINGS
Besides the preceding arrangements, the invention also comprises other arrangements, which will become apparent from the description which follows, with reference to the examples of implementation of the process which is the subject of the present invention, as well as to the attached drawings, in which:
FIG. 1 represents the variations in calcaemia as a function of time (-D-=free calcitonin; -▪-=LGS-calcitonin vector according to the invention);
FIG. 2 represents the difference in AUC between the calcaemia obtained with free calcitonin and that obtained after oral administration of the LGS-calcitonin vectors according to the invention;
FIG. 3 represents the variations in calciuria as a function of time (-▪-=500 kDa LGS-calcitonin vector, -□-=free calcitonin, -□-=300 kDa LGS-calcitonin vector);
FIG. 4 represents the evaluation of the phosphataemia as a function of time (-D-=free calcitonin; -▪-=LGS-calcitonin vector according to the invention);
FIG. 5 represents the difference in AUC between the phosphataemia obtained with free calcitonin and that obtained after oral administration of the LGS-calcitonin vector according to the invention;
FIG. 6 represents the variations in phosphaturia as a function of time (-▪-=LGS-calcitonin vector ((PA-vector) construct) with a molecular weight of at least greater than 500 kDa, which is equal to lipogelosomes® encapsulating calcitonin with a diameter at least greater than 40 nm), -□-=free calcitonin, -□-=LGS-calcitonin vector ((PA-vector) construct) with a molecular weight at least greater than 300 kDa, which is equal to lipogelosomes® encapsulating calcitonin with a diameter of at least greater than 20 nm);
FIG. 7 represents the variations in the SGOT (IU/1) as a function of time (-□-=free calcitonin; -♦-=LGS-calcitonin vector according to the invention;
FIG. 8 represents the variations in the SGPT (IU/1) as a function of time (-□-=free calcitonin; -♦-=LGS-calcitonin vector according to the invention;
FIG. 9 represents the differences in AUC of the SGPT contents between the groups treated with free calcitonin and those treated with an LGS-calcitonin vector according to the invention.
It should be clearly understood, however, that these examples are given purely by way of illustration of the subject-matter of the invention, of which they do not in any way constitute a limitation.
EXAMPLE 1
Texturometry Measurements on the Mixture of Gelatinizing Agents G1 and G2
a) Materials and Methods
The measurements are carried out on a TA-XT2i machine from the company Rhéo. The study relates to the behaviour of gels consisting of a mixture of gelatin and iota and kappa-carrageenans during breaking and relaxation tests.
Concentration of the Samples
Gelatin/iota/kappa-carrageenan mixture (80/17.5/2.5) at a concentration of 7.5% w/v, in a 5 mM Na 2 HPO 4 and 0.9 or 2% NaCl medium.
Preparation of a Solution of Gelatinizing Agents
Sodium chloride is dissolved in a mixer fitted with a turbomixer and a planetary member and containing purified water (15 minutes at 10 rpm), the mixer is raised to a temperature of 75° C. (stirring at 10 rpm for 45 minutes), the gelatinizing agents (gelatin, iota-carrageenans and kappa-carrageenans) are added into the mixer, at 75° C., and the turbomixer is set on at 1500 rpm; the duration of the dissolution step is about 30 minutes; the dissolution is complete when the solution is clear and contains no particles in suspension.
Preparation of the Samples
For the relaxation test, 45 ml of gel are poured, while hot, into a flat-bottomed Petri dish with an outside diameter of 92±2 mm. For the breaking test, 30 ml of gel are poured, while hot, into a flat-bottomed crystallizing basin with an outside diameter of 50±2 mm. The gel is obtained by cooling to a temperature of less than or equal to 37° C. The gel maturation time, which corresponds to a maximum hydration of the gels, is 2.5 days at the study temperature and at rest.
Operating Conditions
For the relaxation test, a compression force is applied to the gel for a given period. The mobile element used is an aluminium cylinder with a diameter of 25 mm, with a pre-speed of 1.0 mm/s, a speed of 0.5 mm/s and a post-speed of 10.0 mm/s. The displacement of the mobile element is 1.0 mm for 30 seconds.
For the breaking test, the mobile element used is an ebonite cylinder 10 mm in diameter with a pre-speed, a speed and a post-speed of 1.0 mm/s. The displacement of the mobile element is 12 mm.
b) Results of a Study at 5° C., with an NaCl Content of 0.9%
Relaxation (%)
minimum value:
81 ± 2.2
maximum value:
89 ± 0.8
Breaking force (g)
minimum value:
1109 ± 25
maximum value:
1503 ± 35
c) Results as a Function of Temperature and of Different NaCl Contents
The operating conditions are identical to those described in a), apart from as regards the displacement of the mobile element used in the relaxation test (displacement of 20% of the total thickness of the gel).
Relaxation (%)
at 5° C.
0.9% NaCl:
89 ± 0.8
2% NaCl:
90 ± 0.2
at 25° C.
0.9% NaCl:
32 ± 3.9
2% NaCl:
38 ± 4.4
at 37° C.
0.9% NaCl:
36 ± 3.7
2% NaCl:
40 ± 4.9
Breaking force (g)
at 5° C.
0.9% NaCl:
1413 ± 66
2% NaCl:
1114 ± 143
at 25° C.
0.9% NaCl:
211 ± 2.7
2% NaCl:
173 ± 1.5
at 37° C.
0.9% NaCl:
25.7 ± 2.4
2% NaCl:
44.7 ± 3.9
EXAMPLE 2
Process for Preparing a Pulverulent Vector According to the Invention Containing Calcitonin
1) Preparation of a Dispersion of Liposomes with a Gelatinized Internal Phase (Lipogelosomes®)
Constituents:
Soybean lecithins
11.915
kg (7.943%)
Gelatin B150
7.149
kg (4.766%)
Iota-carrageenans
1.565
kg (1.043%)
Kappa-carrageenans
0.222
kg (0.148%)
Sucrose
8.936
kg (5.957%)
Sodium chloride
1.073
kg (0.715%)
Purified water
119.15
kg (79.43%)
TOTAL CONTENTS
150.01
kg (100%)
a) Preparation of a dispersion of liposomes
a mixture of:
Gelatin B150
7.149
kg
Iota-carrageenans
1.565
kg
Kappa-carrageenans
0.222
kg
Sucrose
8.936
kg
NaCl
1.073
kg
Na + -chenodeoxycholate
1.131
kg
Purified water
118.00
kg
(qs 150 kg)
is premixed in a mixer at a speed of 10 rpm, the planetary member of which rotates at a speed of 1500 rpm for 1.5 hours under vacuum.
b) Incorporation of Calcitonin
Lowering of the pH of the mixture is carried out using concentrated acetic acid (6 N), by successive additions, until a stable pH of 4.5 is reached. 4.075 g of salmon calcitonin (Bachem Calif.), the specific activity of which is 7017 IU/mg, are then added.
c) Incorporation of Phospholipids into the Solution Obtained in a)
The soybean lecithins (11.915 kg) are added to the premix, in a mixer at a speed of 10 rpm, in which the planetary member rotates at a speed of 1500 rpm, for 5 hours under vacuum (→ formation of an emulsion).
Final dispersion by increasing the stirring speeds of the planetary member (25 rpm) and of the turbomixer (2500 rpm) for a period sufficient to obtain a polydispersity of less than 40%.
A dispersion of lipogelosomes® in aqueous phase is obtained.
Negative staining microscopic observations, cryofracture, cryotransmission and atomic force microscopy: vesicles or assemblies of vesicles having the characteristic appearance of phospholipid bilayers; negative staining makes it possible to observe the more or less pronounced presence of an external gelatinizing agent according to the manufacturing and/or separation process chosen.
d) Tangential Filtration
One volume of the dispersion of lipogelosomes®, which dispersion is obtained during the above steps, is diluted in 20 volumes of hot 0.9% NaCl, with stirring. The diluent (0.9% NaCl) will be supplemented with 8.25×10 −4 % of chenodeoxycholate, depending on the presence of this surfactant in the preceding dispersion. The phase not encapsulated is eliminated by continuous hot tangential ultrafiltration. The ultrafiltration is carried out on a membrane with a selective porosity of 300 or 500 kDa, depending on the desired particle size, of the lipogelosomes®. The product obtained is a suspension of lipogelosomes® encapsulating at least 17% salmon calcitonin, in which the diameters of the liposomes range from 20 nm to 500 nm, when the suspension is ultrafiltered through 300 kDa, and from 40 nm to 500 nm when the suspension is ultrafiltered through 500 kDa.
2) Drying of the Dispersion Obtained
The resulting dispersion of lipogelosomes® in aqueous phase is transferred into a dryer under vacuum (50®100 mbar) for about 4 hours. A fairly homogeneous powder of very pale straw-yellow colour is obtained, containing grains with a diameter of between 0.1 mm and 1 mm.
Under the electron microscope, retraction of the lipid vesicles on themselves was observed, on account of dehydration. Furthermore, it is noted that whereas, in the liquid state, the LGSs are often aggregated inside a homogeneous gelatinized matrix in an environment of numerous isolated vesicular structures, the drying step converts this gelatinous matrix into filaments of dry gelatinizing agent at the surface of the aggregates, but also at the surface of the isolated vesicular structures.
As a variant, the drying is carried out as follows: the dispersion of lipogelosomes® in aqueous phase is distributed directly onto a rotating drum dryer (drum temperature: 120-150° C., speed of rotation 3-6 rpm). The “shavings” obtained are then ground and calibrated on a suitable grid. A lipogelosome® (also referred to hereinbelow as LGS) powder having the characteristics defined above is thus obtained.
The drying can be optimized by adding a filler excipient, for example maltodextrin or β-cyclodextrins.
EXAMPLE 3
Comparative Effects of Free or Encapsulated Calcitonin in Vectors Obtained According to Example 2, After Oral Administration to Rats
The effects of a preparation according to Example 2 on calcaemia, calciuria, phosphataemia and phosphaturia are analysed in comparison with the oral administration of calcitonin in free form. The pharmacokinetics obtained for the two forms of calcitonin administered are also compared.
Other parameters are also analysed: transaminases (SGOT and SGPT) and glycaemia.
It is important to note that the effect of calcitonin in normocalcaemic rats or man is difficult to demonstrate, and that the responses to this hormone are much sharper when pathological individuals (hypercalcaemic individuals) are treated.
Experimental Protocol
Preparation of LGS-calcitonin
See Example 2.
Animals and Pharmacological Treatment
Animals
10 groups of 10 Wistar Ico rats (IOPS AF/Han, IFFA CREDO), i.e. 100 rats in total, 6 weeks old and weighing between 160 and 180 g, were made up.
The weight of the animals was measured at the start of the experiment in order to ensure, as regards this parameter, a homogeneous distribution of the rats in each of the groups.
The 6 experimental groups are prefed for 7 days on a regime based on sterile “AO4” (UAR=Usine d'Alimentation Rationelle (supplier of regimes)).
The rats are fasted and given glucose ad libitum 24 hours before the administration of the experimental doses.
The weight of the animals is monitored before administration of the experimental doses.
Experimental Scheme
The groups A, B, C, D, E, F, G, H, I and J are made up as follows:
group A: 10 control rats from which plasma and urine are taken at time 0.
group B: 10 rats are intubated and 1.8 ml of 500 kDa LGS-Cal suspension (approximate calcitonin concentration: 54 IU/rat, i.e. 330 IU/kg) are administered to each individual. Plasma and urine are taken at time 45 min.
group C: 10 rats are intubated and 1.8 ml of 500 kDa LGS-Cal suspension (approximate calcitonin concentration: 54 IU/rat, i.e. 330 IU/kg) are administered to each individual. Plasma and urine are taken at time 90 min.
group D: 10 rats are intubated and 1.8 ml of 500 kDa LGS-Cal suspension (approximate calcitonin concentration: 54 IU/rat, i.e. 330 IU/kg) are administered to each individual. Plasma and urine are taken at time 180 min.
group E: 10 rats are intubated and 1.8 ml of 500 kDa LGS-Cal suspension (approximate calcitonin concentration: 54 IU/rat, i.e. 330 IU/kg) are administered to each individual. Plasma and urine are taken at time 300 min.
group F: 10 rats are intubated and 1.8 ml of free calcitonin suspension (concentration: 54 IU/rat, i.e. 330 IU/kg) are administered to each individual. Plasma and urine are taken at time 45 min.
group G: 10 rats are intubated and 1.8 ml of free calcitonin suspension (concentration: 54 IU/rat, i.e. 330 IU/kg) are administered to each individual. Plasma and urine are taken at time 90 min.
group H: 10 rats are intubated and 1.8 ml of free calcitonin suspension (concentration: 54 IU/rat, i.e. 330 IU/kg) are administered to each individual. Plasma and urine are taken at time 180 min.
group I: 10 rats are intubated and 1.8 ml of free calcitonin suspension (concentration: 54 IU/rat, i.e. 330 IU/kg) are administered to each individual. Plasma and urine are taken at time 300 min.
group J: 10 rats are intubated and 1.8 ml of 300 kDa LGS-Cal suspension (approximate calcitonin concentration: 36 IU/rat, i.e. 228 IU/kg) are administered to each individual. Plasma and urine are taken at time 90 min.
Anaesthesias: the anaesthesias are performed using Rompun® (2% xylazine; 10 mg/kg)/Imalgene® (10% Ketamine; 60 mg/kg) via intraperitoneal injection according to the chronology indicated in the experimental scheme.
Sampling
Blood samples are taken from the abdominal aorta by catheterization under anaesthesia, at time 0 for group A; time 45 min for groups B and F; time 90 min for groups C, G and J; time 180 min for groups D and H; time 300 min for groups E and I. The bladder is also cannulated and the urine collected according to the same timing as that used for the taking of the blood samples.
The total plasma will be obtained after separation of the blood samples by centrifugation at 3000 rpm for 15 minutes in tubes containing 3.8% EDTA (non-protein anticoagulant).
Analyses
The calcaemia, phosphataemia and transminases will be assayed by colorimetry on each sample of plasma.
Statistical Processing of the Data
The results of the measurements are expressed as an average ±SEM for the ten rats in each group. The data will be compared by means of statistical tests suitable for this type of experimental protocol (studies of the parameters and pharmacokinetics). The statistical test chosen is the ANOVA test or analysis of variance, the significances of the differences are determined by the Fisher test and by the Scheffe test which is more discriminating.
Two methods for expressing the results were used: graphic representation of the averages of 10 values relative to the parameter considered, as well as comparative analysis of the AUCs (areas under the curve). This method of expression makes it possible to assess the differences in the amplitudes in the responses obtained.
The results obtained are represented according to the pharmacokinetic technique: variation of the degree of the parameter considered as a function of time. In this instance, it is not a search for a dose effect.
Results
Pharmacokinetics of the Effect of Free Calcitonin or Calcitonin Encapsulated in LGS-Calc Form, on Calcaemia
FIG. 1 represents the variations in calcaemia as a function of time. The assays used to determine the calcium concentrations were carried out by the colorimetric method given in the Pharmacopoeia. The basal values of the calcaemias (at time 0) correlate very well with the previous data. Each point represents the average of 10 values, i.e. 9 groups of 10 independent rats. The averages are expressed ±SEM. The results are compared by analysis of variance (ANOVA), for non-paired values. The significant differences are symbolized by **. This symbol corresponds to a significance in the highly discriminating Scheffe test.
A transient decrease in calcaemia after oral administration of free calcitonin is observed. It is explained by the fact that during a massive administration of peptide such as calcitonin, a small percentage crosses the intestinal barrier (1%) without being denatured. In this case, 330 IU were administered, which corresponds to a lymphatic passage of 3.3 IU (passage from the intestinal lumen into the plasma, via the lymphatic canal pathway). However, the IV-route effect of calcitonin starts at 0.9 IU. It is thus normal to observe this effect of free calcitonin. The hypocalcaemia observed after oral administration of calcitonin decreases over time to return to the normal level after 90 min.
As regards the LGS-Calc, the same effect at 45 min is observed, but this hypocalcaemic effect is twice as large at 180 min. This fact indicates that the LGS formulation, for an equivalent calcitonin concentration, is more effective in terms of pharmacological effect than free calcitonin. This two-phase phenomenon can be attributed to the activity of calcitonin associated with the external layer of the LGSs (primary action), and the second effect might be due to the calcitonin contained inside the LGSs. A delay effect doubled by an increase in the activity of the PA by a factor of 2 is thus observed.
FIG. 2 represents the difference in the AUC between the calcaemia obtained with free calcitonin and that obtained after oral administration of LGS-Calc. The difference observed is highly significant in the Scheffe test. The AUC corresponds to a cumulative of all the values obtained during the experiment; these values are integrated and then compared. The AUC corresponds to the area under the curve for the variations in calcaemia as a function of time. The smaller this AUC, the greater the hypocalcaemiant effect (since the curve then approaches the x-axis).
Pharmacokinetics of the Effect of Free Calcitonin or Calcitonin Encapsulated in LGS-Calc Form, on Calciuria
The restrictions mentioned with regard to the plasmatic results obtained by atomic absorption are confirmed by analysis of the values obtained on the urine of rats treated with free or encapsulated calcitonin. In point of fact, FIG. 3 corroborates the values of FIG. 1, since a hypocalcaemia is always followed by an increase in calciuria.
Pharmacokinetics of the Effect of Free Calcitonin or Calcitonin Encapsulated in LGS-Calc Form, on Phosphataemia (FIG. 4)
The LGS-Calc and free calcitonin induce a hypo-phosphataemia (colorimetric assay) which continues only in the case of the groups treated with LGS-Calc. The results are significant in the Fisher test. The comparison represented in FIG. 5, of the respective AUCs, very clearly confirms the pharmacokinetic data.
The difference between the two AUCs is significant in the Scheffe test.
Pharmacokinetics of the Effect of Free Calcitonin or Calcitonin Encapsulated in the Form of LGS-Calc, on Phosphaturia (FIG. 6)
The assays on the urine samples were carried out by atomic absorption as in the case of the calciuria (see previously).
These results are less significant than in the case of calciuria. It is thus difficult to draw a conclusion. Nevertheless, it appears that at time 180 min, the effect of the LGS-Calc has a tendency to be greater than that of the non-encapsulated drug.
Toxicological Aspect of the Study
By means of the samples taken, it was possible to carry out the assays of the transaminases during the administration of the two active principles. Analysis of the SGOT contents over time shows a tendency towards hypotoxicity (FIG. 7) of the encapsulated form of calcitonin compared with the free form. This difference is very significant in the Fisher test at time 300 min. However, the comparisons of the AUCs do not show any significant differences as regards the variations in the SGOT contents over time.
This tendency towards moderation of the increase in transaminases (“hypotoxicity”) is confirmed by analysis of the SGPT contents over time (FIG. 8 ).
These data show strong hypotoxicity of the encapsulated form of calcitonin compared with the free form. FIG. 9 shows the differences in AUC for the SGPT contents between the groups treated with free calcitonin and those treated with encapsulated calcitonin.
The difference between the two areas is significant in the Scheffe test.
This effect can be used in particular in the context of administration of highly toxic active principles, in order to reduce the hepatotoxic impact of such substances.
Conclusion
The encapsulation of calcitonin in the LGS form potentiates the crossing of the intestinal barrier.
The comparative effect of the oral administration shows a genuine potential of the LGS form, which is all the greater since it is now possible to stabilize this structure in powder form.
The two-phase hypocalcaemiant effect of LGS-Calc can be explained by the distribution of calcitonin at the surface and in the centre of the LGSs.
This experiment makes it possible to evaluate the hypotoxicity of the LGS-Calc form compared with the free form, which appears to be more toxic.
The data demonstrating the superiority of the LGS-Calc form over free calcitonin were acquired using the assay method recommended in the pharmacopoeia.
The two peaks of hypocalcaemia brought about after oral administration of the two forms of PA were specified: 45 and 180 min after administration.
The “delay” effect of the LGS-Calc might be due to a gradual release into the intestine of microspheres obtained from a stock matrix: the LGS-Calc concentrates, which gradually penetrate the intestinal barrier.
EXAMPLE 4
Increase in the Bioavailability of the Principles Encapsulated in the Lipogelosome and Derived Forms; Comparison Between Liposomes and Lipogelosomes®
1. Comparison of Resistance or Stability of the Lipogelosome® (LGS) and Standard Liposome (LS) Forms
The LGSs make it possible to prepare pharmaceutical forms (powder) which are impossible to prepare with the conventional liposomal forms; only the LGSs withstand the physiological conditions: pH, temperature, intestinal motility, enzymes, which gives them the capacity to be administered via the oral or pulmonary route, whereas the LSs are destructured when they are administered via such routes.
a) Resistance to pH and to Intestinal Bile Salts
Series of incubations of LGS and of LS, for 1 hour at 37° C. in the presence of bile salt (taurodeoxycholate) with detergent power, and thus destructuring power with respect to lipid vesicles, are carried out. The results show that for a bile salt concentration of 0.25 mM, the LGSs are 3 times as resistant as the LSs. The resistance of the structures is analysed by laser granulometry (variation in the level of counting of the particles, indicated by the variation in the diffraction of a laser, in KHz).
Comparison of the structure (observed by laser granulometry) of LGSs and LSs after incubation for 1 hour at variable pH values shows that the LGSs are stable from pH=2.5 to 9, whereas the LSs are predominantly in tact only at pH=6.3.
The LGSs are more resistant than the LSs to the pH levels and the detergent concentrations encountered in the stomach; this makes it possible to deduce that the LSs are degraded in the stomach, whereas the LGSs are resistant for longer.
b) Resistance to Seric Medium, to Temperature and to Stirring
Series of incubations of LGS and of LS were carried out for 24 hours at 37° C. with stirring. The lipid phases of the LGSs and LSs, which are rigorously identical in terms of composition, were labelled in the same way with an isotope ( 14 -C) The products derived from degradation of the two types of structure: LS or LGS, were analysed over time. It appears in the light of the results that the lipid constituents of the LSs are released more easily than the lipid constituents of the LGSs.
These results show that the LGS form is more stable than the LS form.
c) Comparison of the Leakage of the Encapsulated Active Principles from LGSs and from LSs
An active principle (AP) of small size (500 Da) was encapsulated in LGSs and in LSs, in the same amount. Thereafter, the two preparations were stirred at 37° C. in a seric medium, and the release of the encapsulated AP was measured. The amount of AP released from the LSs is 60% higher than the amount of AP released from the LGSs (1.6 units of AP for the LS; 1.01 units of AP for the LGS).
By virtue of this significantly higher stability of the LGSs, solid pharmaceutical forms can be prepared and an oral administration is possible, whereas these could not be envisaged with liposomes of conventional formulation.
2. Comparison of the Bioavailability of the Lipogelosome® Form and Conventional Liposome Form, in a Cell Model
The differences in cellular internalization of a marker or of an AP when these molecules are encapsulated in LGS (lipogelosome®) forms or in LS (liposome) forms were analysed.
a) Comparison of the Cellular Internalizations of Liposomes and Lipogelosomes®
The LSs and LGSs were labelled using radioactive probes or fluorescent probes and, after a period of incubation in a medium in the presence of human macrophages (THP1 strain) in culture at 37° C., the comparative internalization of the two types of structure (LS and LGS) was analysed at the end of incubation, the incubation times being identical. The analysis of the internalizations was carried out by various analytical methods.
A. Fluorescence Microscopy
The images show an internalization of the LSs and LGSs, but in the case of the LSs, the distribution of the signal is homogeneous, whereas the distribution of the signal for the LGSs is localized in punctiform intracellular structures.
This result shows that the LGSs are degraded less rapidly intracellularly than the LS structures (in which the signal diffuses more rapidly in the cell).
Thus, an effect of slow diffusion of the active principles encapsulated in LGSs appears, whereas it does not exist for the LSs.
B. Radiolabelling
Intracellular counting of the radiolabelled LGSs and radiolabelled LSs shows that the LGSs are internalized 2.5 times as much as the LSs under the same experimental conditions.
The LGSs are internalized in greater amount than the LSs: this fact shows that the cellular bioavailability of LGSs is greater than that of LSs, which is due to the difference between the two liposomal structures: the presence of a specific temperature-reversible gel in the internal phase of the LGS, which radiates out up to the surface of the particle, gives LGSs a preferential cellular uptake property.
C. Flow Cytometry
These experiments are based on the comparative cellular endocytosis of LGS and LS labelled with a fluorescent probe. After incubation, the cells are harvested and then passed to the flow cytometer, which quantifies the fluorescent signal in each cell. The spectra obtained show that the cells incubated with LGSs emit 2.5 times as much fluorescent signal as the cells incubated with LSs.
The LGSs are internalized 2.5 times as much as the LSs: this fact shows that the cellular bioavailability of LGSs is greater than that of LSs.
b) Comparative Cellular Pharmacology of Lipogelosomes®—AP/free AP
A. AZT and 3TC, Effects on Macrophages in Culture
In these experiments, LGSs encapsulating AZT or 3TC were incubated with human macrophage cells. The cytotoxicities of the free products or of the products encapsulated in the LGSs were analysed. The results show that the encapsulated APs are 150 times more effective than free AZT or 3CT, in terms of toxicity with respect to macrophages in culture.
These experiments show that, for equal doses, the encapsulated AP is 150 times more active with respect to macrophages than free AP, which is quite probably due to its better cellular internalization.
B. Doxorubicin and PEG 4000, Effects on Hepatocytes and Differentiated Intestinal Epithelial Cells, in Culture
The cellular internalization of two molecules: doxorubicin and PEG 4000, was compared, according to whether they are in free form or encapsulated in the form of LGS.
Under the same experimental conditions of time and concentration, the fact that the molecule is encapsulated brings about an increase in its cellular incorporation or in its pharmacological activity with respect to cells of hepatic or intestinal origin, by a factor ranging from 1.5 to 3.
These experiments show that the bioavailability of the molecules encapsulated in the form of LGS is increased relative to their free form, on intestinal epithelial cells or on hepatic parenchymal cells.
c) Explanation of the Modified Bioavailability of Molecules When They are in the Form of LGSs
Liposomes (LS) are usually internalized into cells by a process of membrane fusion, known as passive diffusion, i.e. a process which does not bring into question any second messengers responsible for the expression of a membrane receptor.
However, LGSs differ from LSs by the presence of a specific temperature-reversible gel in the internal phase of the LGS, which radiates out up to the surface of the particle, as well as by the presence of a gel film over its external surface. This gel is of proteo-sugar nature (mixture of gelatin and κ and ι carrageenans).
The differences in cellular internalizations and thus in bioavailability between LSs and the LGSs according to the invention lie essentially in the presence and composition of this gel.
Differentiated or undifferentiated intestinal cells (strains: HT29, HT29gal, T84) were cultured on a semi-porous filter (diffusion chamber). LGSs were incubated with these cells in the presence or absence of cpt-cAMP. In the presence of cpt-cAMP, the internalization of the LGSs is increased by a factor of 2.
This experiment shows that the internalization of LGSs is a cAMP-dependent phenomenon. Moreover, the curve of LGS internalization as a function of the dose shows that the LGS internalization phenomenon is saturable. These two essential facts show that the internalization of LGSs is mediated by a receptor. This internalization process thus differs from processes of endocytosis by fusion of conventional liposomes, which is not dependent on a receptor. Thus, the optimized bioavailability of drugs encapsulated in LGSs is explained by the involvement of a receptor which is specific to LGSs.
d) Bioavailability of the Lipogelosomes® Forms In vivo in Rats
see Example 3
e) Bioavailability of the Lipogelosomes® Forms on the Diffusion Chamber Model
Intestinal epithelial cells were cultured to confluence on a semi-porous filter in order to obtain a biocompartmental system, separating a “plasmatic” medium from an “intestinal lumen” medium. LGSs were placed on the “intestinal lumen” side and then, after an incubation period, the “plasmatic” medium was analysed.
In this compartment, laser granulometry reveals structures with the same characteristics as the LGSs deposited at the start of the experiment in the “intestinal lumen” compartment. The addition of a proportion of CDCA (chenodeoxycholate) to the LGS formulation, increases the number of particles found in the “plasmatic” compartment.
These experiments show that a proportion of LGSs crosses the intestinal epithelium, quite probably by a process of paracellular passage or transcytosis. This passage is increased when the LGS formulation is modified by the addition of CDCA.
Thus, it is possible to optimize the intestinal transepithelial passage (after oral administration, for example) of molecules encapsulated in LGSs; the LGS form makes it possible to increase the intestinal bioavailability of the encapsulated molecules, and this property is accentuated when chenodeoxycholate is included in the LGS formulation.
As emerges from the text hereinabove, the invention is not limited in any way to the methods for implementing it, preparing it or applying it which have just been described in greater detail; on the contrary, it encompasses all the variants which may occur to a person skilled in the art, without departing from the context or scope of the present invention.
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The invention concerns liposome vectors, in powder form, of active principles, and more particularly active principles sensitive to digestive and/or plasmatic degradation, such as proteins, and their application as medicine. Said liposome vectors of active principles consist of a powder composition essentially constituted of unilamellar liposomes comprising an external lipid phase consisting of class 4 lipids (phospholipids), optionally associated with class 2 substances, class 3 substances and/or class 5 substances and an internal aqueous nucleus consisting of a mixture M of at least two different non-polymerisable gelling agents (G1 and G2) whereof the gel-sol phase transition is not less than 37° C., G1 being selected among gelatines and carrageenans and G2 being selected among carrageenans with properties different from the carrageenans selected for G1, and celluloses, which liposomes have a diameter ranging between 20 nm and 1 mm, preferably between 20 nm and 500 nm; said composition having the form of particulate units with an average particle diameter between 10 mm and 1000 mm, formed by one or several of said liposomes, enclosed in a sheath selected in the group consisting of a dehydrated thermoreversible aqueous gel identical to said internal nucleus aqueous gel, dextrins or a mixture thereof, such that they contain, on an average, 10 to 10 liposomes per gram of powder; and at least an active principle contained, as the case may be, either in the gelled internal nucleus or in the external lipid phase.
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This application is a divisional of application Ser. No. 09/135,696 filing date Aug. 18, 1998, U.S. Pat. No. 6,074,888.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to micro-optical components and, more particularly, to a method for producing monolithic micro-optical components using standard semiconductor fabrication techniques.
2. Discussion of the Related Art
Compact and simple lens systems for micro-optical devices are essential in optical communication systems. Generally, an optical communication system is comprised of independently fabricated micro-optical components that are attached to microbenches. Present optical systems use a variety of techniques for fabricating micro-optical components and for obtaining efficient coupling between micro-optical components and other micro-optical devices. For instance, these optical systems might be manually assembled from very small parts by persons using tweezers and a microscope. Although this manual approach may be feasible for limited quantities of systems, difficulty remains in achieving high output production. On the other hand, current automated assembly techniques fail to achieve the precision alignment and quality needed for most microcomponent systems.
Therefore, it is desirable to provide a monolithic micro-optical system for use in various optical communication applications. Since there are less individual components to align, the complexity of the assembly process will be decreased. Some assembly steps are entirely eliminated with the formation of a monolithic structure. This reduction in assembly complexity improves alignment accuracy, increases reliability and decreases assembly costs for a micro-optical system. The present invention solves these problems by using standard semiconductor fabrication techniques to manufacture a monolithic micro-optical system.
SUMMARY OF THE INVENTION
The present invention relates to a method for fabricating monolithic micro-optical components. The construction of the micro-optical components is accomplished by using standard semiconductor fabrication techniques. The method comprises, in one embodiment, the steps of depositing an etch stop layer onto a semiconductor substrate; depositing an optical component layer onto the etch stop layer; coating the entire surface of the optical component layer with a photoresist material; applying a photoresist mask to the photoresist material on the optical component layer; selectively etching away the optical component layer to form at least one optical column; forming a pedestal for each of the optical columns by selectively etching away the etch stop layer; and finally polishing each of the optical columns, thereby forming monolithic optical components. The method may optionally include the step of removing the photoresist mask from each of the optical columns prior to polishing the optical columns, as well as the step of depositing an antireflectivity coating onto each of the optical components.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objectives and advantages of the present invention will be apparent to those skilled in the art upon reading the following detailed description and upon reference to the drawings in which:
FIG. 1 is a perspective view of a micro-optical system having a micro-optical component in accordance with the present invention;
FIG. 2 is a top view of a micro-optical duplexer system implementing an exemplary micro-optical component of the present invention; and
FIG. 3 is a side view illustration of a semiconductor wafer in accordance with the present invention;
FIG. 4 is a top view illustration of a photoresist mask in accordance with the present invention;
FIG. 5 is side view illustration of a photoresist mask in accordance with the present invention;
FIG. 6 is side view illustration of initial optical columns being formed by selectively etching away an optical component layer in accordance with the present invention;
FIG. 7 is a side view illustration of pedestals being formed by an undercutting etching process in accordance with the present invention;
FIG. 8 is a side view illustration of the selectively etched surface of the optical columns, where the photoresist mask has been removed in accordance with the present invention; and
FIG. 9 is a side view illustration optical components that have been polished into shape in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
While the invention is described herein with reference to illustrative embodiments for particular applications, it should be understood that the invention is not limited thereto. Those having ordinary skill in the art and access to the teachings provided herein will recognize additional modifications, applications and embodiments within the scope thereof and additional fields in which the present invention would be of significant utility.
A micro-optical system 10 for use in an optical fiber network application is depicted in FIG. 1 . Micro-optical system 10 is a monolithic structure that is created (as further described below) using standard semiconductor fabrication techniques. Micro-optical system 10 includes an micro-optical component 14 connected by a pedestal 16 to a semiconductor substrate 12 . The micro-optical component 14 is shown as a spherical ball lens, but is intended to represent various optical components, such as a cylindrical or conical lens, a concave or convex lens, a prism or any other related optical devices. Each of these components or combinations thereof serve to focus light or redirect an optical beam between other photonic components (e.g., receivers, transmitters and repeaters) and may be used to construct a micro-optical system.
A micro-optical duplexer 20 is depicted in FIG. 2 as an exemplary implementation of a micro-optical system in an optical fiber network application. Micro-optical duplexer 20 is being used as a bi-directional transceiver in a fiber network. Micro-optical duplex 20 includes a microbench 30 that is mounted onto a housing 22 (e.g., Kovar housing) which has a feedthrough for an optic fiber 24 . A single-mode fiber 24 serves as the connection to a remote fiber network (not shown). A photo diode 26 and laser diode 28 are also mounted to housing 22 . The tolerances in positioning and fixing these active devices on housing 22 are on the order of microns.
Microbench 30 (4 mm×14 mm×1 mm) provides the various passive micro-optical components needed by the system. A right spherical lens 32 , a left spherical lens 34 and a wavelength filter 36 are each formed and passively aligned on microbench 30 . In order to have a collimated laser beam for a distance of several millimeters, these spherical lenses have a diameter on the order of 900 um. To achieve the high accuracy that is required for this passive alignment, microbench 30 , including these micro-optical components, are fabricated in accordance with the principles of the present invention.
In operation of the duplexer 20 , light with the wavelength — =1300 nm is emitted from laser diode 28 and collimated by right spherical lens 32 before being passed through wavefilter 36 and focused onto the end face of the single-mode fiber 24 . Light with the wavelength — =−1550 nm enters through fiber 24 and is collimated by left spherical lens 34 prior to being reflected at wavelength filter 36 and detected by photo diode 26 . While depicting these micro-optical components in the context of a micro-optical duplexer, this discussion is intended to adequately teach one skilled in the art to implement micro-optical components of the present invention in a variety of optical applications.
FIGS. 3-9 illustrate the steps for fabricating a micro-optical component of the present invention. FIG. 3 shows a side view of a typical semiconductor wafer 40 . Commonly known epitaxy techniques (i.e., LPE, MOCVD, etc.) are used to grow precisely calibrated thin single-crystal semiconductor layers. An indium phosphide (InP) substrate 42 serves as a microbench for the micro-optical components. A pedestal layer 44 with a thickness on the order of 2-5 microns is deposited onto substrate 42 . This layer is comprised of a ternary material (i.e. InGaAs or AlInAs) quaternary material (ie., InGaAsP) and determines the pedestal height for each optical component. Using the accuracy of the epi-crystal growth technology, the pedestal height can be controlled at the angstroms tolerance level. An optical component layer 46 is then deposited onto pedestal layer 44 . Optical component layer 46 should be deposited at a thickness correlating to the maximum required lens dimensions (at least 20 microns thick). Indium phosphide (InP) is also chosen for optical component layer 46 because of its etching characteristics as well as its ability to form a high index lens with low aberrations.
In an alternative preferred embodiment, the optical component layer 46 and substrate 42 may be comprised of gallium arsenide (GaAs), whereas the pedestal layer 44 is comprised of aluminum gallium arsenide (AlGaAs). It is important to note that other materials can be used for these various layers. For example, the optical component layer 46 and substrate 42 may be any III-V semiconductor material and may include indium phosphide (InP), gallium arsenide (GaAs), indium arsenide (InAs) and gallium phosphide (GaP). Moreover, although two different materials having similar thermal expansion coefficients may be used, the same material is preferably used for both optical component layer 46 and microbench substrate 42 . In this way, optical alignment problems caused by thermal expansion are minimized in optical applications where wide temperature variations are common (i.e., in military and space applications).
Photolithography and other known wafer fabrication techniques are then used to fabricate the optical components. First, a photoresist coating is applied over the entire surface of the optical component layer 46 . The preferred photoresist material is 2-ethoxpyethylacetate (60%) and n-butyl acetate (5%) in xylene and hexamethyldisilozane (HDMS) because of its suitability for use in the dry etching of deep profiles on indium phosphide (InP) and related semiconductor materials. Photoresist material may also include 2-ethoxyethylacetate+n-butyl acetate in xylene solvent, 2-ethoxyethylacetate+n-butyl acetate in xylene and silicon dioxide (SiO 2 ) precoated, 2-ethoxyethylacetate+n-butyl acetate in xylene and silicon nitride (Si 3 N 4 ) precoated, silicon dioxide (SiO 2 ) and complex silicon nitride (Si x N y ), or aluminum oxide (Al 2 O 3 ) precoated.
A mask is used to transfer a lens pattern onto the optical component layer. Lens patterns are chosen based on the quantity and type of lens required for a particular optical application. As will be apparent to one skilled in the art, an initial lens shape is dependent on the particular mask design. Depending on the type of optical component (e.g., spherical ball lens, cylindrical ball lens, conical ball lens, convex lens, concave lens, prism, or a combination of these components), a corresponding mask will be used to establish the shape of the initial optical column. As best seen in FIG. 4, a mask is a pattern in which the regions to be exposed are opaque and the protected regions are shaded. The mask is aligned with optical component layer 46 such that when the photoresist material is exposed to an ultraviolet (UV) light source through the mask, the appropriate lens pattern is transferred onto the surface of the optical component layer. As a result, a photoresist mask 50 , as illustrated in FIG. 5, is formed on the surface of optical component layer 46 .
Next, initial optical columns for each of the micro-optical components is formed by dry etching away the unwanted optical component material. These initial optical columns 52 are shown in FIG. 6 . As will be apparent to one skilled in the art, electron cyclotron resonance (ECR) etching, inductive couple plasma (ICP) etching or reactive-ion etching (RIE) are commonly employed dry etching techniques. Dry etch mixtures may include argon and hydrochloric acid (Ar/HCl), argon hydrogen and chlorine (AR/Cl 2 /H 2 ), argon and hydrobromic acid (Ar/HBr), argon and bromine (Ar/Br 2 ), argon and chlorine (Ar/Cl 2 ), argon and methane and hydrogen (Ar/CH 4 /H 2 ), methyl iodide (H 3 Cl), bromine iodide (IBr), methane and hydrogen and sulfur fluoride (CH 4 /H 2 /SF 6 ), ethyl iodide (C 2 H 5 I), isoethyl iodide (C 3 H 7 I), hexafluoride carbon and hydrogen (C 2 F 6 /H 2 ), or dichloro-difluoro carbon and oxygen (CCl 2 F 2 /O 2 ).
Referring to FIG. 7, wet selective etching with controlled undercutting will provide a pedestal support or stem 54 for each of these optical columns. By using a selective (quaternary) etching solution, pedestal layer 44 is selectively removed from underneath the optical columns without effecting the binary or other material comprising the optical columns and substrate layer. Moreover, this undercutting etching approach provides sufficient space below each of the optical columns for polishing and subsequent formation of the optical components. Wet selective etching chemicals may include potassium hydroxide:potassium ferricyanide:deionized water (KOH:K 3 Fe(CN) 6 :H 2 O), lactic acid:nitric acid (10 CH 3 CH 2 OCOOH:HNO 3 ), hydrochloric acid:nitric acid (HCl:n HNO 3 , where n>5), phosphoric acid:hydrogen peroxide:deionized water (H 3 PO 4 :H 2 O 2 :8H 2 O), nitric acid (HNO 3 ), sulfuric acid:hydrogen peroxide:deionized water (H 2 SO 4 :H 2 O 2 :H 2 O), nitric acid:tartaric acid:deionized water (n HNO 3 :HOOC(CH 2 O) 2 COOH:H 2 O, where n between 1 and 10) and hydrofluoric acid:hydrogen peroxide:deionized water (HF:H 2 O 2 :n H 2 O, where n between 1 and 20).
After the above-described etching process, the photoresist coating is removed from the optical component layer in FIG. 8 . Using acetone, the photoresist mask is removed from the surface of the optical columns. Following the removal of the photoresist mask, the acetone is removed from the surface of the optical columns with isopropanol and then the isopropanol is removed from the surface of the optical columns using deionized water. The photoresist can also be removed using photoresist stripper, potassium hydroxide, or other equivalent alkaline chemicals followed by a deionized water rinse. Finally, oxides and photoresist residues are removed from the surface of the optical columns using potassium hydroxide (KOH).
Lastly, these optical columns are further etched and polished into optical components 56 as seen in FIG. 9. A selective wet etching process continues the formation process of an optical component For instance, a weak non-orientation binary selective etching solution (e.g., hydrofloric acid:hydrobromic acid (1HF:10HBr), hydrobromic acid:acetic acid (HBr:CH 3 COOH) or hydrochloric acid:propylene glycol (HCl:CH 3 CHOHCH 2 OH)) can be used to polish and round off the edges and corners of the optical column. Since this solution will etch the corners and edges faster than other portions of the optical columns, the corners are rounded off to form lenses, thereby shaping the optical columns into optical components. It should also be noted that this solution should not etch the quaternary material of the pedestals.
Furthermore, a weak chemical polishing solution (e.g., hydrobromic acid:acetic acid:deionized water(n HBr:CH 3 COOH:H20, where n between 1 and 4), or hydrochloric acid:propylene glycol (HCl:CH 3 CHOHCH 2 OH)) can be used to polish the surfaces of an optical column. In this case, polishing is usually performed at a very low temperature, typically between −10 degrees and 20 degrees centigrade. To polish the surface of optical lens, emerge the wafer which contains the formed lens into the polishing solution, agitate the wafer for a calibrated period of time and then rinse in deionized water. Allow wafer to dry before proceeding to the remaining steps.
Once an optical component has been formed, an antireflectivity or filtering coating can also be applied to any one of these optical components to maximize transmitted light. For the present invention, a crystal mixture of antireflectivity (AR) coating which contains magnesium fluoride (MgF), aluminum oxide (Al 2 O 3 ), hafnium fluoride (HfF), silicon dioxide (SiO 2 ), and silicon nitride (Si 3 N 4 ) is deposited over the entire surface of each optical component. This coating may be applied by using electron beam evaporation, sputtering, chemical vapor deposition, or other similar processes.
The foregoing discloses and describes merely exemplary embodiments of the present invention. One skilled in the art will readily recognize from such discussion, and from the accompanying drawings and claims, that various changes, modifications and variations can be made therein without departing from the spirit and scope of the present invention.
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A method for fabricating a monolithic micro-optical component. The construction of the micro-optical components is accomplished by using standard semiconductor fabrication techniques. The method comprises the steps of depositing an etch stop layer ( 44 ) onto a semiconductor substrate ( 42 ); depositing an optical component layer ( 46 ) onto the etch stop layer ( 44 ); coating the entire surface of the optical component layer with a photoresist material; applying a photoresist mask ( 50 ) to the photoresist material on the optical component layer ( 46 ); selectively etching away the optical component layer ( 46 ) to form at least one optical column ( 52 ); forming a pedestal ( 54 ) for each of the optical columns ( 52 ) by selectively etching away the etch stop layer ( 44 ); and finally polishing each of the optical columns ( 52 ), thereby forming monolithic optical components ( 56 ). The method may optionally include the step of removing the photoresist mask from each of the optical columns prior to polishing the optical columns, as well as the step of depositing an antireflectivity coating onto each of the optical components.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the priority of German Application Nos. P 43 32 496.7 filed Sep. 24, 1993 and P 44 22 574.1 filed Jun. 28, 1994, which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
This invention relates to a method and an apparatus for detaching fiber tufts from textile fiber bales formed of cotton, chemical fibers or the like. The apparatus has a detaching device which travels back-and-forth above the fiber bales and which may be lowered thereonto. The detaching device removes fiber tufts from the upper surface of the fiber bales and advances the fiber tufts to a tuft transporting device. The bale height is divided into at least three detaching zones.
The fiber bales are delivered to the spinning preparation plant in a compressed state. After removing the constraining ties, such as straps, wire or the like, the bales, by virtue of their natural resiliency, expand in a vertical direction. Consequently, the bales from which fiber tufts are to be removed do not have a uniform density as viewed in the vertical direction. The fiber bales have the greatest density in a mid zone. As a result of such an uneven density distribution, upon detaching fiber tufts from an originally upper bale zone lying above the mid zone and later, from an originally lower bale zone lying below the mid zone, less fiber tufts (by weight) are detached and delivered than during the fiber tuft detachment from the mid zone of the bale. This means that during a starting period and during a terminal period of the detaching operation performed on a bale series, the downstream-connected machines are supplied with less fiber material (measured in weight) per time unit than during the detaching period when fiber tufts are removed from the mid zone of the bales.
In accordance with a known process, the adaptation of the weight of the fiber tuft quantities (production quantities) delivered by the detaching device per time unit to the different bale densities is achieved by varying the vertical feed of the detaching device for consecutive passes. In such a method the depth of detaching operation in the upper bale zone in which the density of the fiber material increases downwardly, is gradually decreased from a predetermined maximum detaching depth down to a detaching depth determined for the mid zone. The upper bale zone is delimited by a predetermined number of passes of the detaching device. In the mid zone where the bale density is the greatest, the predetermined detaching depth is maintained constant to thus delimit such mid zone. In accordance with a further known process, in the lower bale zone (decreasing density in the vertical direction) additionally the detaching depth is gradually increased; the maximum detaching depth and the number of passes of the detaching device are predetermined. In case, however, the output quantities have to be rapidly altered and the vertical feed is altered during one or several passes, the difficulty is encountered that the upper surface of the bales will be wavy which is an undesirable phenomenon. It is a further disadvantage of the known process that the fiber tuft dimensions fluctuate when the detaching depth is altered.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved method and apparatus of the above-outlined type from which the discussed disadvantages are eliminated and which, in particular, ensures an optimal detachment of the fiber tufts and, particularly, a uniform output weight and a uniform tuft size during the entire detaching operation performed on a fiber bale series until such bale series is fully consumed.
This object and others to become apparent as the specification progresses, are accomplished by the invention, according to which, briefly stated, the speed of back-and-forth travel of the detaching device is altered as a function of the actual height of the bale on which the detaching operation is performed.
Thus, according to the invention, the non-uniform density of the fiber bales in the upper and/or lower zones is compensated for by altering the travelling speed of the detaching device as a function of the actual height of the bales. The measures according to the invention ensure that no changes in the production quantities will occur in the fiber processing machines which are connected in a production line after (downstream of) the fiber tuft removing apparatus (bale opener). Thus, such downstream-arranged fiber processing machines receive a uniform supply of fiber material, that is, the unlike density of the fiber bales in the lower and/or upper bale zones is compensated for as early as the detaching operation by changing the travelling speed. According to a particularly advantageous feature of the invention, the travel speed alteration is combined with a vertical feed alteration to provide for a flexible adaptation of the detaching operation to the various bale thicknesses, for obtaining the required output and for ensuring uniform fiber tuft dimensions.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic sectional front elevational view of a travelling bale opener incorporating the invention.
FIG. 2a is a schematic sectional side elevational view of the apparatus shown in FIG. 1.
FIG. 2b is an enlarged schematic side elevational detail of the construction shown in FIG. 2a.
FIG. 3 is a schematic sectional front elevational view of a bale opener including a location transmitter for height position determination.
FIG. 4 is a block diagram of a control system for controlling the speed of a propelling motor and a lifting motor.
FIG. 5 is a diagram showing a bale opener travelling speed as a function of the actual height of the fiber bale submitted to a detaching operation.
FIG. 6 is a fragmentary side elevational view of a fiber bale showing actual height values of the bale zone I.
FIG. 7 is a schematic side elevational view of a row of fiber bales and a detaching device at the beginning of a pass and showing the change of the detaching depth a by lowering the detaching device.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning to FIGS. 1, 2a and 3, there is illustrated therein a bale opener 1 which may be, for example, a BLENDOMAT BDT model, manufactured by Tru/ tzschler GmbH & Co. KG, Mo/ nchengladbach, Germany. The bale opener 1 which detaches fiber tufts from the top of fiber bales arranged in a fiber bale series 3 has a tower 2 which travels back-and-forth in the direction of arrows A and B parallel to the bale series 3. The bale opener tower 2 supports, by means of a holding device 7, a laterally projecting detaching device 4 which has a rapidly rotating detaching mechanism, formed, for example, of two oppositely rotating, parallel arranged opening rolls (detaching rolls) 5 and 6. The fiber tufts detached by the opening rolls 5 and 6 are carried away by suction through a suction hood in which the detaching rolls 5 and 6 are disposed and a suction duct 9 pneumatically coupled to the hood. The detaching device 4 further has two slowly rotating pressing rolls 10 and 11 arranged parallel to the detaching rolls 5 and 6. The detaching device 4 may be vertically lowered or raised as indicated by the arrows C and D. The bale opener 1 works on the upper face 3a of the bale series 3 in a horizontal direction.
Referring in particular to FIG. 1, the tower 2 is supported on a carriage 23 which runs on rails 12a, 12b oriented parallel to the length of the bale series 3. The carriage wheels 14 and 15 are driven by a propelling motor 13 which may be an rpm-variable, frequency-controlled asynchronous motor and by means of which the travelling speed v of the bale opener is set or changed. The holding device 7 supporting the detaching device 4 is suspended by means of a cable 18a and end rollers 16, 17 and is balanced by a counterweight 18. A lifting motor 19, which may be an rpm-variable, frequency-controlled asynchronous motor is mounted on the carriage 23 and applies a raising or lowering force on the detaching device 4 by belt or chain transmission elements 20, 20a.
The displacement of the carriage 23, the tower 2 and the detaching device 4 as a unit in the horizontal direction (x-coordinate in FIG. 2a) by the propelling motor 13 and the displacement of the detaching device 4 in the vertical direction (y-coordinate in FIG. 1) by the lifting motor 19 are coordinated by a control apparatus 21 connected to the motors 13 and 19 by control cables 22 as will be discussed later with reference to FIG. 4. The tower 2 is mounted on the carriage 23 for rotation about a vertical axis.
The suction conduit 9 opens into a suction channel 24 which is fixed on the floor between the rails 12a, 12b and extends parallel thereto. For determining the location of the detaching device in the vertical direction (y-axis), an angular position transmitter 25 is affixed to the deflecting roller 16.
The various vertically superposed bale zones have the following characteristics:
Zone I: designated as the upper bale zone having a height h I and a fiber material density which increases in a downward direction.
Zone II: designated as the middle bale zone having a height h II and a constant, maximum fiber material density.
Zone III: designated as the lower bale zone having a height h III and is characterized by a fiber material density which decreases downwardly.
As shown in FIG. 2b, the propelling motor 13 transmits its driving torque to the wheel 14b of the carriage 23 with the intermediary of a gearing 27, a sprocket 28, a chain 29, a sprocket 20, a chain 31 and a sprocket 32.
Turning to the block diagram of FIG. 4, there is shown a control device 21 which may be a microcomputer coupled with an inputting device 35. The control device 21 is coupled with a position-determining device 36 for the horizontal travel (x-axis), such as an incremental rotary position indicator 26 mounted on the carriage 23 and a position-determining device 37 such as an incremental rotary position indicator 25 mounted on the end roller 16 for the vertical displacement (y-axis). As an alternative, the height position-determining device may include, as shown in FIG. 3, a magnet 33, secured to the vertically movable holding device 7, cooperating with induction coils 34 mounted stationarily on the tower 2 in a vertical sequence. The control device 21 is further connected with the propelling motor 13 with the intermediary of an amplifier 38 (including a control electronics and/or a frequency converter) and with the lifting motor 19 with the intermediary of an amplifier 39.
As shown in FIG. 5, the travelling speed is, in the fiber bale zone I, reduced in eight steps of 0.5 m/min each, from 12 m/min to 8 m/min and in the zone III the travelling speed is increased in eight steps of 0.5 m/min each, from 8 m/min to 12 m/min. In zone II the travelling speed remains constant at 8 m/min. Such a function curve which thus represents the travelling speed v as a function of the actual momentary bale height h is, together with the initial bale height, inputted in the control device 21 and, accordingly, the travelling speed v is changed by the propelling motor 13 in the zones I and III.
FIG. 6 shows for the zone I the actual bale heights corresponding to the relationships shown in FIG. 5.
______________________________________Initial bale height: h = 150 mmHeight of zone I: h.sub.1 = 1500 - 1200 = 300 mmFeed: a = 5 mm (constant)Number of passes: D = 300:5 = 60Actual height after h.sub.1 = 1500 - 5 = 1495 mmthe first pass:Number of the speed 8steps:Actual bale height in the first speed step: ##STR1##______________________________________
At the actual height h 37 .5 the travelling speed is lowered from 12.0 m/min to 11.5 m/min.
Turning to FIG. 7, the detaching device 4 has been moved above the bale series 3 in the direction A to a position beyond the bale series 3. Subsequently, the detaching device 4 is lowered (direction D) by the inputted or calculated distance a (detaching depth or feed). Thereafter the detaching device 4 travels over the bale series 3 in the direction B. During the back-and-forth travel fiber tufts are removed by the detaching device 4 from the upper face 3a of the bale of the bale series 3.
In the description which follows, the process according to the invention will be set forth in more detail in conjunction with examples.
First, the magnitude of the vertical feed a is selected (set) by the inputter 35. For each fiber bale group (bale series) a feed a between 0.1 and 19.9 mm is inputted. The feed a is the thickness of a fiber material layer which, during each pass, is removed from the individual fiber bales or fiber bale series by the opening rolls 5, 6. The required feed a of the detaching device 4 is adapted to the required output.
The microcomputer (control device) 21 which may be a BLENDCOMMANDER BC model, manufactured by Tru/ tzschler GmbH & Co. KG, Mo/ nchengladbach, Germany, automatically senses the height h (initial bale height) of the bale series that has been set up and the detected values are stored. The programming of the control device 21 is effected, for example, as disclosed in German Patent No. 3,335,793. For determining the bale group height h, the detaching device 4 carries three optical barriers: a frontal, upper optical barrier, a frontal, lower optical barrier and a rear optical barrier. A determination of the bale group height h is effected with the aid of all three optical barriers during the first pass (programming pass). In this operation the detaching device 4 travels such that its travel path approximately "hugs" the contour of the upper face 3a of the bales. The detection of the height is effected alternatingly by the two frontal optical barriers. The determination (detection) of the gap between bale groups is effected by the rear optical barrier. The momentary height of the detaching device 4, corresponding essentially to the bale height h, is stored in the control device 21 in short intervals. After the first pass, based on these data, average values are computed for the individual bale groups. The average values are used as the basis for further processing. The detaching device 4 travels above the bale series 3 and the machine detects the location of their beginning and end, as well as their height h while production is already in progress. The control device (computer) 21 divides the height of the bale series by the selected vertical feed a, resulting in the number of passes of the detaching device 4 which are required for completely consuming the bale series 3. The control device 21 divides the height of the other bale series by the computed number of passes; this results for each of these bale series in the feed a which is required to ensure that all bale series are simultaneously consumed.
After a one-time determination of the height h the latter is stored in the control device 21 and the actual height h 1 -h n is in each instance corrected by the amount by which the detaching device 4 travels lower (feed a) during a pass. In this manner, the actual heights h 1 -h n of the bale series are at all times known in the control device (computer) 21 and it is thus simple to vary the travel speed v as a function of such actual heights. There is a direct and exclusive relationship between the bale height h and the travelling speed v:
______________________________________Example: Bale Height Travelling Speed______________________________________ 1500-1400 12 m/min 1399-1200 11 m/min 1199-1100 10 m/min 1099-1000 9 m/min 999-300 9 m/min 299-200 8 m/min 199-100 10 m/min 99-0 11 m/min______________________________________
As to when a certain travelling speed v applies may be individually set and reproduced. The relationship between the bale height h and the travelling speed v is determined by an inputtable mathematical function. This function may be very simple (for example, purely linear) or relatively complex (for example, a cosine function or the like). Each once-determined and optimized relationship is storable in the program memory of the control device 21 so that it may be directly retrieved to reproduce an event. The determination and storage of the relationship between bale height h and travelling speed v is separately inputtable dependent on the present respective bale series 3 and working range. Further, the magnitude of the speed variation may be made additionally dependent of the set feed a, that is, in case of a very large feed a only a certain travelling speed v is permissible. In this manner the detaching device 4 may be protected from overload and possible clogging. The travelling speed v and the feed a may be varied as a function of the bale height h 1 -h n . The corresponding relationships are freely selectable, they may be stored and further, they may be retrieved at any time. In machines which have a monitor, a graphic programming is possible on the monitor screen. Travelling speed and/or feed profiles may be relatively easily produced, stored and retrieved.
The invention will be further explained by way of examples where the change of the travelling speed v and/or the feed a are given. Also encompassed are embodiments in which during one forward or reverse pass (as indicated by the arrows A and B, respectively) the travelling speed v is varied. Further, there are included embodiments in which the travelling speed v and/or the feed a are not varied at each forward or reverse pass, according to requirements. The travel speed v and/or the feed a may increase and decrease in the zone I and/or the zone III. As a rule, the travelling speed v and/or the feed a is constant within one forward or reverse pass. It is also possible to vary the feed a in the zones I and III in, for example, two to four steps. The steps of the speed variation are basically independent from the feed a.
As illustrated in FIG. 5, the travelling speed in zones I and III is, in each instance, changed in eight steps, while the number of passes is, however, substantially greater. According to the invention, the change of the travelling speed depends from the actual bale height. The speed change may, however, be combined with a feed change.
EXAMPLE 1
______________________________________Zone I: Travelling speed v 12.0 m/min to 8 m/min (decreas- ing) in eight steps of 0.5 m/min each Feed a 5 mm (constant)Zone II: Travelling speed v 8 m/min (constant) Feed a 5 mm (constant)Zone III: Travelling speed v 8 m/min to 12.0 m/min (increas- ing) Feed a 5 mm (constant)______________________________________
The increasing and decreasing density in the zones I and III is compensated for by the decreasing and, respectively, increasing travelling speed v (FIG. 5). The feed a is constant in all three zones I, II and III.
EXAMPLE 2
______________________________________Zone I: Travelling speed v 12 m/min to 8 m/min (decreas- ing) in 8 stages, 0.5 m/min each Feed a 6 mm (constant)Zone II: Travelling speed v 10 m/min (constant) Feed a 5 mm (constant)Zone III: Travelling speed v 8 m/min to 12 m/min (increasing) Feed a 6 mm (constant)______________________________________
The increasing and decreasing density in the zones I and III is compensated for by the decreasing and increasing travelling speed v. The constant speed v in the zone II is between the highest and, respectively, lowest travelling speed v in the zones I and III. The feed a is greater in zones I and III than in zone II. With the increased feed a the circumstance is taken into account that the density of the fiber material in the zones I and III is less than in the zone II. In this manner the effect of the travelling speed is counteracted. The travelling speed v may not exceed a predetermined maximum value; nevertheless, by means of the increased feed a a high travelling speed v may be achieved.
EXAMPLE 3
______________________________________Zone I: Travelling speed v 10.0 m/min (constant) Feed a 8 mm to 5 mm (decreasing)Zone II: Travelling speed v 10.0 m/min (constant) Feed a 5 mm (constant)Zone III: Travelling speed v 8 m/min to 12 m/min (increasing) in eight steps, 0.5 m/min each Feed a 6 mm (constant)______________________________________
The travelling speed v remains constant in zone I. The increasing density in zone I is compensated for by the decreasing feed a. Additionally, the decreasing feed a assists in the planarization (level equalization) of adjoining bales of the bale series 3. Such equalization is needed, because based on the pressure and the nature of the fibers slight height differences may be present after the individual bales of the bale series expand upon removal of the bale ties. In zone III the decreasing density is compensated for by the increasing travelling speed v and a feed a which is increased with respect to that in zone II. The problem of different heights does not occur in zone III because the bales press with their weight (for example, 220 kg) on the zone III and also, they are supported on a planar floor in the plant. Therefore, in zone III a constant feed a may be selected.
In zone III the decreasing density is compensated for by varying the travelling speed v in combination with the constantly increased feed a.
EXAMPLE 4
______________________________________Zone I: Travelling speed v 12.0 m/min to 10.0 m/min (de- creasing) Feed a 6 mm to 3 mm (decreasing)Zone II: Travelling speed v 10.0 m/min (constant) Feed a 3 mm (constant)Zone III: Travelling speed v 10.0 to 12 m/min (increasing) Feed a 3 mm to 6 mm (increasing)______________________________________
EXAMPLE 5
______________________________________Zone I: Travelling speed v 10.0 m/min (constant) Feed a 8 mm to 5 mm (decreasing)Zone II: Travelling speed v 9.0 m/min (constant) Feed a 6 mm (constant)Zone III: Travelling speed v 8 m/min to 12 m/min (increasing) in eight steps 0.5 m/min each Feed a 6 mm (constant)______________________________________
The feed a is gradually reduced in zone I from 8 mm to 5 mm. The lowest feed a of 5 mm is not equal to the feed a predetermined for the zone II; rather, in zone II an increased feed a of 6 mm is held constant. The thus increased output quantities are compensated for by a reduced travelling speed v of 9 m/min.
EXAMPLE 6
______________________________________Zone I: Travelling speed v 10.0 m/min (constant) Feed a 8 mm to 5 mm (decreasing)Zone II: Travelling speed v 10.0 m/min (constant) Feed a 6 mm and 4 mm (alternating)Zone III: Travelling speed v 8 m/min to 12 m/min (increasing) in eight steps, 0.5 m/min each Feed a 6 mm (constant)______________________________________
The feed a is gradually reduced in zone I from 8 mm to 5 mm. The lowest feed a of 5 mm is not the feed a determined for the zone II; rather, in zone II there is set an alternating feed of 6 mm and 4 mm. Thus, the feed a is not maintained constant in the zone II.
According to the Examples 5 and 6, the own weight of the bale presses on the zone III (rather the zone I) so that the looser layer in zone III is slightly denser (lesser height) than the loose layer in zone I. For this reason the loose layers in the zones I and III are compensated for in different ways, that is, in zone I by a reduction of the feed and in zone III by an increasing travelling speed.
In zones I and/or III the change of the density is compensated for by altering the travelling speed v and the feed a. This embodiment provides for a flexible adaptation of the detached fiber tuft quantities. The travelling speed v and the feed a may not exceed predetermined maximum values so that a mutual partial substitution or, as the case may be, a complementation is effected.
It is added that according to the invention it is also feasible to vary the travelling speed v as a function of the fill level and/or fiber material requirement of a storage device, mixer, fill chute, cleaner, card or other machine arranged downstream of the bale opener in the fiber processing line. The travelling speed v may also be altered as a function of the bale hardness.
It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims.
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A method of detaching fiber tufts from an upper surface of fiber bales by a detaching device. Each fiber bale has, prior to performing a detaching operation thereon, a height portion defining an upper zone in which a fiber density increases downwardly; a height portion defining a lower zone in which the fiber density decreases downwardly; and a height portion defining a middle zone in which the fiber density is at a maximum, constant value as viewed vertically. The method includes the steps of propelling the detaching device at a travelling speed above the fiber bales in forward and return passes; detaching fiber tufts from the upper bale surface during the passes; periodically displacing the detaching device with a vertical feed as the bales are consumed; advancing the removed fiber tufts to a fiber tuft advancing device; and varying the travelling speed as a function of the decreasing actual height of the fiber bales.
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FIELD OF THE INVENTION
The present invention relates to an adjustment and/or alignment arrangement for the positioning of a toolholder relative to a toolholder mounting in machine tools. More particularly, the present invention relates to such arrangement involving a pivotal movement, with an adjustment part which cooperates with a setting part.
BACKGROUND OF THE INVENTION
Toolholders, such as spindleheads having drivable or rotatably processing tools, are constructed in the turrets of turning machines, lathes or drills, for example, to facilitate off-center machining of turning parts on a turning machine, such as a machine tool. The interface or cutting point for that processing is determined between spindleheads and tool disks of tool turrets by the DIN 69880-11 (publication September 1994, page 305ff) standard. With such spindleheads, in which the tool axis of the drivable or rotatable cutting tool is identical with the central axis of the mounting bore according to the aforementioned DIN standard, and the bore is aligned parallel to the normal or vertical axis of the turning machine, it is not necessary to adjust the cutting tool. An adjustment is necessary, however, in the case of spindleheads in which the tool axis is not identical with the central axis of the mounting bores as in the aforementioned DIN standard. In these cases, for precise machining, the tool point must be aligned first along the normal or vertical axis of the machine tool, especially of a turning machine. Similarly, with the so-called counter-rotation of the spindle, the central axes of the mounting bores are arranged in a star arrangement on the tool disk of the tool turret, whereby the interior processing tools are first to be aligned parallel to the rotary axis of the turning machine.
A toolholder, for example in the form of a spindlehead, can be centered with the aid of the mounting bore, as in the cited DIN standard. Although it can be centered in axial alignment, it cannot be aligned relative to another axis extending perpendicular to the bore central axis. In that case, there are other known adjustment and/or alignment arrangements. With a known adjustment and/or alignment arrangement, such as in DE 39 29 802 C1, the toolholder includes two set screws arranged opposite one another serving as setting members. The set screws work together on an adjustment part which is arranged on the toolholder mounting. This solution has the drawback that any toolholder with any arrangement in the associated toolholder mounting is to be adjusted in the selected setting by means of the setting or adjustment screws. Modifications of the adjustment and/or alignment arrangement occur with multiple removals and insertions of the toolholder, which lead to inaccuracies. Also, the adjustment process by means of manipulation of two set screws separately from one another is not simple and is correspondingly time-consuming.
To overcome the drawbacks of this state of the art, DE 195 48 151 A1 discloses providing associated adjustment parts as an adjustment and/or alignment arrangement on both the toolholder and the toolholder mounting. The adjustment parts, upon their interconnection as form-locking elements, engage in one another without play. However, the accurate and precise fitting in one another without play requires high manufacturing cost for production of the arrangement, so that this solution turns out to be very costly.
A toolholder insert disclosed DE 31 50 355 C2 is especially for drill rods or the like with a shaft-like toolholder for a cutting insert. An adjustment sheathing is screwed onto an exterior threading of the toolholder. The adjustment sheathing engages the tool holder with a flange on the one side of a stationary collar, and with a spring ring or the like mounted on the adjustment sheathing. The toolholder is supported on the one hand on the other side of the collar and on the other hand on a collar-like detent of the adjustment sheathing. Axial tightness between structural parts is produced by the spring ring. Relative positioning by pivoting the toolholder cannot be attained with the known axial adjustment mechanism. Furthermore, the known arrangement is complicated in set-up and is expensive in production because of the plurality of parts. It is also difficult to handle.
SUMMARY OF THE INVENTION
Objects of the present invention are to provide an adjustment and/or alignment arrangement which is of simple construction and consequently of low cost, while to a great extent facilitates the desired adjustment simply and operationally securely.
The foregoing objects are basically obtained by an adjustment arrangement for pivotally positioning a toolholder relative to a toolholder mounting in a machine tool, comprising an adjustment part and a setting part coupled to the adjustment part. The setting part has a mounting housing, a guiding part receiving the adjustment part and being guided for longitudinal sliding motion in the mounting housing, an accumulator biasing the guiding part in one longitudinal direction of the sliding motion of the guiding part, and an operation part controlling the guiding part in an opposite longitudinal direction of the sliding motion of the guiding part.
With a relatively few simple structural components according to the present invention, an operationally secure adjustment and/or alignment arrangement can be realized. Highly precise, costly adaptations between the adjustment part and the setting part can be dropped. Furthermore, the setting and adjustment procedure can be undertaken effectively by means of one single operation part, which remarkably simplifies manipulation of the adjustment and/or alignment arrangement, especially in subsequent operation on the processing machines.
With the adjustment and/or alignment arrangement according to the present invention in the same type and direction of operation, the pivot adjustment movement can be carried out for the relative positioning between the toolholder and the toolholder mounting in such a manner that precise adjustment of the driving axle with the machine tool main axle, for example, the normal or vertical axis, is possible.
In one preferred embodiment of the adjustment and/or arrangement according to the present invention, the adjustment part is mounted securely on the toolholder mounting and the setting part is securely mounted on the toolholder. Furthermore, the setting part can be configured as a sliding block having an engagement point for the adjustment part. Thus, the sliding block together with the adjustment part can assume a stationary position; and the setting part with the mounting housing is moved together with the toolholder around the relevant stationary structural group. The basic machine structural parts, such as spring-biased sliding blocks provided guided in housings, are described for a tool changing device described in De 33 18 603 A1, the subject matter of which is hereby incorporated by reference.
Having the accumulator formed of at least one compression spring, particularly a disk spring, has been proven to be particularly operationally secure. The spring can engage on one side of the sliding block; and the operation part in the form of an operating screw can engage on its other side.
Other objects, advantages and salient features of the present invention will become apparent from the following detailed description, which, taken in conjunction with the annexed drawings, disclose a preferred embodiment of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring to the drawings which form a part of this disclosure:
FIG. 1 is a side elevational view in section of a toolholder arranged in a toolholder mounting in the form of a wedge-like spindlehead according to the present invention;
FIG. 2 is a partial top plan view in section of the wedge-like spindlehead taken along line I—I of FIG. 1; and
FIG. 3 is an enlarged top plan view in section of the adjustment and/or alignment arrangement of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
The adjustment and/or alignment arrangement of the present invention serves for positioning of a toolholder 10 relative to a toolholder mounting 12 in machine tools, especially turning machines (not shown). Toolholder 10 can be in the form of a wedge-shaped spindlehead with a first driving axle or axis 14 . In order to drive a cutting tool (not shown), first driving axle 14 drives a second driving axle or axis 16 extending perpendicular to the first axle. The aforementioned cutting tool is conventional, and thus, is not described further, and can be inserted over the tool mounting 18 , driven by driving axles 14 and 16 for a manufacturing process. The first driving axle 14 is guided rotatably in a toolholder shaft 20 , provided with teeth 22 around the exterior periphery in a conventional manner. If toolholder 10 is inserted through its toolholder shaft 20 into the associated circular toolholder mounting 12 , corresponding teeth 26 of a clamping 24 , according to a position shown in FIG. 2, engage teeth 22 toolholder shaft 20 , and thus, affix the wedge-like spindlehead tightly on toolholder mounting 12 . For the release of clamping member 24 , it is moved back along its longitudinal axis 28 , whereupon the teeth 22 and 26 are disengaged with one another and toolholder 10 is released.
In the case of rotary processing, first driving axle 14 can extend along the normal or vertical axis of the turning machine. Consequently, second driving axle 16 is at a right angle to driving axle 14 . With counter-rotation of the spindle, the arrangement of toolholder 10 is such that second driving axle 16 is aligned parallel to the vertical axis of the turning machine and first driving axle 14 is perpendicular thereto, transverse to the turning machine vertical axis. In both cases, however, the tool point of the cutting tool, and consequently the second driving axle 16 , is aligned exactly in relation to the vertical axis, in order to avoid inaccuracies. For this purpose, the adjustment and/or alignment arrangement has an adjustment part 30 which cooperates with a setting part indicated in it entirety as 32 . As is shown particularly in FIG. 3, setting part 32 has a mobile guiding part 36 guiding adjustment part 30 counter to the effect of force accumulator 34 , whereby guiding part 36 can be controlled by operation part 38 .
As shown particularly in FIG. 1, adjustment part 30 is mounted securely on toolholder mounting 12 , and setting part 32 is in turn securely mounted on toolholder 10 . Setting part 32 is provided with a mounting housing 40 , in which the guiding part 36 in the form of a sliding block 42 is longitudinally slidably guided. Guiding part 36 incorporates an engagement point for adjustment/alignment part 30 . Accumulator 34 is formed of at least one disk spring or a plurality of disk springs arranged one behind the other in series. As is particularly clear in FIG. 3, these disk springs engage with their one free end on the one end 44 of sliding block 42 and are supported with their other end on the interior of mounting housing 40 . For the formation of a specific contact surface for accumulator 34 in the form of the disk spring arrangement, sliding block 42 has a shelf-like ledge 46 at the associated end. The shelf-like ledge of the disk spring arrangement is at least partially surrounded. Shelf-like ledge 46 , however in any case, is at sufficient distance from the interior of mounting housing 40 that the open spring path of the disk spring arrangement is not blocked. Besides, with the shelf-like ledge 46 , there is a detent capacity relative to mounting housing 40 in case of overload or breakdown of accumulator 34 .
The other side 48 of sliding block 42 engages operation part 38 in the form of an operating screw 50 . Screw 50 has an interior hexagonal cutout for the engagement of a operating tool (not shown), for example, an interior hexagonal wrench. Operating screw 50 is guided into and out of mounting housing 40 by means of its exterior threading 52 and interior threading 54 of the housing. A separate structural part strikes with a detent part 56 on the other end 48 of sliding block 42 . Under the effect of accumulator 34 , sliding block 42 is pressed on the detent part 56 of operating screw 50 . Interior threading 54 , which opens into the environment, is cut in such a manner into a length of mounting housing 40 that the entire pivot path provided for second driving axle 16 and consequently for toolholder 10 is obtained.
Sliding block 42 has a middle bore 58 as an engagement point. The diameter of bore 58 is greater than the diameter of adjustment part 30 in the form of an adjustment pivot pin 60 . As shown particularly in FIG. 1 pivot pin 60 is received and fitted tightly in a shaped bore 62 in toolholder mounting 12 . Within middle bore 58 , in turn, a detent surface 64 for pivot 60 is provided and is part of a detent screw 66 . Detent screw 66 extends through the middle of the disk spring arrangement and is screwed into sliding block 42 . The free end of detent screw 66 is guided movably in the wall of mounting housing 40 , and can be secured by means of a traditional Loctite connection within the interior threading of sliding block 42 . At the free end of detent screw 66 , an engagement point for an operating tool (not shown) is present for moving detent screw 66 within sliding block 42 , to limit the free space within middle bore 58 of sliding block 42 .
An anti-torsion member 70 (FIG. 3) is provided so that with such a setting process, sliding block 42 cannot be turned within its guide 68 . Anti-torsion member 70 has a set screw 72 which is threadedly engaged in mounting housing 40 . One free contact end of set screw 72 is engaged in a longitudinal groove 74 of sliding block 42 . Thus, on the one hand an effective anti-torsion member 70 is supplied. On the other hand, the longitudinal mobility of mounting housing 40 relative to sliding block 42 is guaranteed, the same as before. Also, set screw 72 can be clamped permanently by a traditional Loctite connection within mounting housing 40 .
Mounting housing 40 has a flange-like extension 76 on both mounting housing sides in the area of the engagement of set screw 72 . Each extension is penetrated by a clamping screw 78 , which serves (FIG. 2) for subsequent clamping of setting part 32 on toolholder 10 . In order to be able to attain a certain tolerance equalization for this clamping, clamping screws 78 extend through enlarged bores 80 within flange-like extensions 76 . Consequently the distance between the clamping screws 78 can be varied.
As shown in FIG. 1, adjustment part 30 projects position-centered over the specific bearing surface 82 of toolholder mounting 12 , i.e., defines a center position for the apparatus and can be overlapped by setting part 32 in extension of contract surfact 84 of toolhholder 10 for engagement. Bearing surface 82 and contact surface 84 are made to provide in exact plane-parallel contact of toolholder 10 on toolholder mounting 12 . Setting part 32 engages on the side of a projecting shelf-like ledge 86 of toolholder 10 . Shelf-like ledge 86 is at a slightly greater height than setting part 32 when viewed in alignment with adjustment part 30 .
The adjustment and/or alignment arrangement according to the present invention is now described in greater detail by one exemplary, practical adjustment procedure. First the middle bore 58 of sling block 42 is adjusted with detent screw 66 for diameter adjustment to relate to the diameter of adjustment pivot pin 60 . Then, mounting housing 40 is clamped by means of clamping screw 78 onto toolholder 10 , especially at its projecting shelf-like ledge 86 . Since the diameter of pin-like adjustment pivot pin 60 is of very narrow tolerance, the basic setting preferably occurs only one time during the tool manufacture. In the later operation, on site, the basic setting can be corrected upon the appearance of spots of wear on adjustment pivot pin 60 or with modification of the angle setting.
Toolholder 10 is then set in the mounting opening of toolholder mounting 12 , for example, of a set-up theory or pattern. Approximately 10 to 25% of the maximum clamping force is clamped/tightened over clamping member 24 . However it is also possible to undertake the setting on the machine directly. Subsequently, toolholder 10 and consequently both driving axles 14 and 16 are set in their angular settings, while operating screw 50 thrusts sliding block 42 against the force of the disk spring arrangement (accumulator 34 ). Thus, toolholder 10 can be rotated, first of all around first driving axle 14 and in such a manner as to carry along second driving axle 16 in a pivotal direction, which stands in alignment in FIG. 1 perpendicular to the plane of the drawing. FIG. 2 indicates the possibility of deflection of second driving axle 16 in both directions around its midpoint indicated by arrows 88 .
The force of the spring arrangement is preferably set so that it is in any case greater than the processing forces of the cutting tool of toolholder 10 effecting the angle setting. Basically, sliding block 42 remains in its clamped position on adjustment pivot pin 60 . With operation of operating screw 50 , mounting housing 40 , projecting shelf-like ledge 86 and toolholder 10 are moved around a path preterminable by first driving axle 14 . If the operating screw 50 is driven in the clockwise direction, second driving axle 16 likewise pivots in the clockwise direction and vice versa, so that the operator effectively finds an adequate operation for the angle adjustment.
While a particular embodiment has been chosen to illustrate the invention, it will be understood by those skilled in the art that various changes and modifications can be made therein without departing from the scope of the invention as defined in the appended claims.
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An adjustment and/or alignment arrangement positions a toolholder ( 10 ) relative to a toolholder mounting ( 12 ) in machine tools in a pivot movement. An adjustment part ( 30 ) cooperates with a setting part ( 32 ). The setting part ( 32 ) is provided with a mounting housing ( 40 ), in which, counter to the effect of an accumulator ( 34 ), a guiding part ( 36 ) for the adjustment part ( 30 ) is guided longitudinally slidably. The guiding part ( 36 ) can be controlled by an operation part ( 38 ). The adjustment and/or alignment arrangement is of simple construction, and consequently, is of low cost, while to a great extent facilitates the desired adjustment simply and operationally securely.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an analog accumulator, more especially an analog accumulator used in association with a solid state image analyzer for averaging and storing the fixed pattern noise FPN.
In fact, in solid state image analyzers there frequently exists non uniformity of the dark signal which is reproduced in each line. This non uniformity or fixed noise is generally called FPN. To eliminate this non uniformity which causes a defect on the images to which the eye is very sensitive, it is stored and subtracted from each line of the video signal.
2. Description of the Prior Art
This operation is at present carried out using digital circuits in the following way:
the video signal of one or more black lines placed at the beginning of the frame, namely the parasite signal FPN, is digitalized using an analog-digital converter then stored in a random access memory. This memory is then read for each line, converted into analog form using a digital-analog converter and the parasite FPN signal is subtracted from the video signal so as to give a corrected video signal free of FPN.
The disadvantage of this technique is that it introduces a noise relative to time called "rain noise" which results from storing the time related noise during acquisition of the fixed noise called FPN.
Consequently, different improvements have been made to the basic circuits for reducing the amplitude of the "rain noise". One or these improvements is described, for example, in the European patent application published under n°89 203 in the name of Sony Corporation and consists in adding a level selector. However, these improvements increase the complexity so the manufacturing cost of the basic circuit which already comprises an analog-digital converter, a random access memory and a digital-analog converter.
Furthermore, when the parasite signal to be subtracted, mainly the FPN, is constant or slowly varying during the frames, the rain noise may be reduced by accumulating and averaging several fixed noise of FPN lines. In fact, accumulation of several FPN lines improves the FPN/rain noise ratio by a factor √M, if the accumulation takes place over M lines.
SUMMARY OF THE INVENTION
The present invention overcomes the disadvantages of digital circuits by providing an analog accumulator for accumulating N analog pieces of information and reading them non destructively.
The object of the present invention is therefore to provide an analog accumulator for integrating N analog pieces of information over M sequences, comprising a series-parallel demultiplexer with N stages for receiving and storing N pieces of information, N storage means connected to the N stages of the demultiplexer, each storage means effecting, for the M sequences, the summation and temporary storage of the analog informations of corresponding rank, N reading means connected to the N storage means for reading the analog informations contained in the storage means without destroying them and a parallel/series multiplexer with N stages, each stage of which is connected to one of the reading means so as to deliver, at the end of the M sequences, several times the N accumulated analog pieces of information.
In a preferred embodiment, particularly well adapted to the case where the accumulator is associated with a solid state image analyzer for obtaining a fixed FPN noise with reduced rain noise, the analog accumulator according to the invention comprises a charge transfer shift register with a series input and parallel outputs having N stages, N floating storage diodes each connected to a stage of the shift register through a passage gate, each diode providing, for the M sequences, accumulation and temporary storage of the analog informations of corresponding rank, N non destructive reading means each formed by a floating input diode for receiving a drive charge input by an injection means, an injection gate connected to the floating storage diode separating the floating input diode from a charge removal drain and the corresponding input stage of a charge transfer shift register with parallel inputs and a series output having N stages, so as to deliver in series, at the end of the M sequences, several times the N accumulated analog pieces of information.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages of the present invention will be clear from reading the description of one embodiment made with reference to the accompanying drawings in which:
FIG. 1 is a top view of an analog accumulator in accordance with the present invention;
FIGS. 2a to 2d are respectively a view partially in perspective and in schematical section through II--II of FIG. 1 and diagrams showing the evolution of the surface potentials as a function of time;
FIGS. 3a and 3b are respectively a sectional view of the floating input diode and of the injection gate, a diagram showing the evolution of the surface potentials under these elements when the drive charge has been injected and a curve showing the evolution of the surface potential as a function of time on the floating diode; and
FIG. 4 is a view for explaining the process used for forming floating storage and input diodes.
In the Figures, the same reference designate the same elements but for the sake of clarity the sizes and proportions of the different elements have not been respected.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is described with reference to an analog accumulator associated with a solid stage image analyzer for obtaining a fixed noise called FPN with low rain noise. However, it is obvious for a man skilled in the art that the analog accumulator of the present invention may also be used whenever one or more pieces of averaged analog information are required which must be read several times.
A preferred embodiment of an analog accumulator in accordance with the present invention will now be described with reference to FIGS. 1 and 2a. This accumulator was constructed in the form of an integrated circuit using the CCD (charge coupled device) technology on a P type silicon substrate. Preferably, as shown in FIG. 2a, the accumulator is formed on an N zone formed in the P type silicon substrate so as to have volume transfer, which limits the transfer noise. However, it is obvious for a man skilled in the art that this accumulator may be formed on other substrates such as an N type silicon substrate, a gallium arsenide substrate or similar and that, in addition, the transfer may take place on the surface.
The accumulator of FIG. 1 comprises first of all a voltage-charge conversion stage shown symbolically by the diode D e and the gate G e which transforms the analog voltages corresponding to the FPN signal into charge amounts Q n ,m. This voltage-charge conversion stage is followed by a charge transfer shift register R of CCD type, with a series input and parallel outputs which, in the embodiment shown, has two phase operation. The charge transfer shift register R which receives N charge amounts corresponding to the N analog voltages of a sequence comprises N stages e 1 to e N . Each stage of the register is formed in a way known per se by two electrode pairs each comprising a transfer electrode and a storage electrode. Each electrode pair is connected to an AC control potential φ 1 and φ 2 and in phase opposition. Furthermore, the storage electrode of the electrode pair controlled by φ 1 is used as output and it is referenced G 1 in FIG. 2a. The electrode G 1 of each stage of the shift register R is separated from a charge storage means by a passage gate G p connected to a potential φ P , as shown in FIG. 2a.
The charge storage and accumulation means are formed by floating diodes C S1 . . . C Si . . . C Ni formed in a way known per se by an N + type diffusion in the N zone of the substrate.
The analog accumulator of the present invention further comprises means for non destructive reading of the charges which have been accumulated in the diodes C S1 . . . C Si . . . C SN . These non destructive reading means are formed by an input floating diode C E1 ,C E2 , . . . C Ei . . . C EN , a charge injection gate G i adjacent the corresponding input diode C E1 to C EN and connected by a connection C to the corresponding storage diode C S1 to C SN . This charge injection gate G i separates the input diodes C E1 to C EN from a charge removal drain formed by a passage gate G D connected to a potential V GD and a diode D polarized by the voltage V D and from stages e' 1 to e' N of a charge transfer shift register R' performing multiplexing of the accumulator charge amount. Furthermore, the non destructive reading means comprise a device for injecting a drive charge Q e whose role will be explained in detail further on. In the embodiment shown in FIG. 1, the device for injecting the drive charge Q e is formed by the charge transfer shift register R' which is provided with a series injection device shown schematically by the diode D' e and the passage gate G' e . The use of register R' allows an identical drive charge Q e to be obtained at the level of each stage e' 1 to e' N corresponding to each non destructive reading means. Furthermore, the charge transfer shift register R' is used for delivering in series the N analog voltages corresponding to the N charge amounts accumulated in the storage means C S1 to C SN .
This charge transfer shift register R' is a two phase CCD type register with a structure identical to shift register R. It is controlled by control potentials φ' 1 and φ' 2 in phase opposition whose frequency may be different from the frequency of the control potentials φ 1 and φ 2 of register R as will be explained hereafter.
Furthermore, the storage electrode of the electrode pair controlled by φ' 1 is used as input. It is referenced G' 1 in FIG. 2a and is separated from the reading means by a passage gate G' p connected to a potential φ' p .
The shift register R' is connected at the output to a charge-voltage conversion stage represented symbolically by the diode D L and amplifier A.
Operation of the analog accumulator of the present invention will now be described with reference more particularly to FIGS. 2b and 2d. This operation is described in a case where the analog accumulator is associated with a solid stage image analyzer for accumulating the FPN signal and obtaining at the output a parasite signal representative of the FPN signal with low rain noise.
Several lines containing the signal to be subtracted, namely the FPN signal, are first of all accumulated in the storage means C S1 to C SN . For carrying out this operation, whenever the video signal of a black line containing the signal to be subtracted appears, the video signal is connected to the series input of the shift register R, namely to diode D e . The shift register R then loads all its stages e 1 to e N with a charge Q nm proportional to the FPN signal but containing the time related noise.
During the line suppression time, the potential φ P applied to gate G P goes to a high level as shown in FIG. 2b and stages e 1 to e N of the CCD register R are emptied into the storage diodes C S1 to C SN .
By beginning this operation again, several black lines are accumulated in a storage means C S1 to C SN . In fact, the time for writing in the storage means C S1 to C SN is chosen as a function of the desired noise reduction and within the dynamic range of the storage means at the temperature of use.
Furthermore, the sum of the charges arriving successively after M input sequences on the storage means C S1 to C SN formed by floating diodes is accompanied by the variation of potential ΔV N from a reference potential defined above, the value of this variation is given by the equation: ##EQU1##
Once the charges are accumulated, the N storage means C S1 to C SN are read in a non destructive way by reading means and the charge transfer shift register R' with parallel inputs and a series output.
During each reading operation, a uniform drive charge Q e is injected into each stage of register R'.
Then, during line suppression, the following transfers are effected:
charge Q e is then transferred to the input diodes C E1 to C EN as shown in FIG. 2b.
Charge Q e is chosen so as to be greater than the accumulated signal charge Q S .
In addition, since the injection gates G i are floating gates connected by a connection C to the storage means C Si , the potential variation ΔV N is also applied to the injection gates G i and the result is a variation of the surface potential under each gate G i such that: ##EQU2## with C oxi the oxide capacity under the corresponding gate and C depi the depletion capacity.
Thus, the charge Q e , greater than Q S , is distributed into diode C Ei and under gate G i .
Then, as shown in FIG. 2c, the excess of charge Q e with respect to the potential barrier Δφ Si is eliminated. For that, the potential of gate G d is lowered so that its surface potential is at a level higher than the surface potential under gate G i so that the excess charges are removed towards diode D.
There then remains on diode C Ei a charge Q Si such that: ##EQU3##
Then, as shown in FIG. 2d, the charge Q S present on diode C Si is fed into the corresponding stage e i of the charge transfer shift register R by raising the potential φ p of gate G p when φ 1 is at a high level. This causes on gate G i a variation of potential in the reverse direction to the initial variation, that is to say that the potential barrier Δφ Si disappears. Potential φ P is brought to a high level and charge Q Si present in diode C Ei is transferred to the corresponding stage e' i of the shift register R'. The evolution of the potential on the floating diodes as a function of time has been shown in FIG. 3b and, by referring to FIG. 3a which corresponds to the right hand part of FIG. 2b, the evolution of the charges in the diode can be seen.
Since these operations are carried out during line suppression, on each stage e' 1 to e' N of the shift register R', charges Q Si are available proportional to the charges Q S which will be read and subtracted, after adjustment of the gain, for each video line coming from a solid stage image analyzer for the reading operation can be carried out during each line suppression, the accumulated charges Q S being stored in the shift register R and possibly fed back to the storage means for another reading operation. The advantage of the analog accumulator of the present invention and of the reading method used with this accumulator is that it allows an FPN signal to be obtained at the output with a limited time-related noise without adding additional noises at each conversion.
In fact, the time-related noise on the signal charge Q S is reduced by the successive summations. Furthermore, the time-related reading noise of the input diodes C Ei is low if care is taken to use reduced capacities.
Furthermore, so as to avoid introducing a multiplicative FPN which corresponds to the injection gain when a voltage-charge conversion is carried out in one stage, the dispersions on this injection gain should be reduced as much as possible. ##EQU4##
Consequently, in order to reduce the dispersions over the injection gain, a weakly doped substrate should be used (for example a silicon P substrate doped to 5.10 14 atoms/cm 3 with an N zone formed by implantation of phosphorous at a dose of 10 12 atoms/cm 3 ) with a small oxide thickness (for example 500 to 1000 Å) so that:
C.sub.depi <<C.sub.oxi
and ##EQU5##
Thus the dispersion on this component of the gain will be very small.
Furthermore, it is important to define diodes C Si and C Ei by the same masking level and strictly symmetrically as shown in FIG. 4 so as to have
C.sub.Si =αC.sub.Ei
Consequently, if diodes C Si and C Ei vary from one stage to the other, their relationship remains constant and so Q Si =αQ S is obtained.
Moreover, the advantage of the above described non destructive parallel injection method is to determine, stage by stage, the charge injected by the difference between two surface potentials under the same gate. The injected charge does not depend on the absolute value of these potentials. It is therefore insensitive to the MOS threshold variations due to the spatial inhomogeneities of the material or the manufacturing process.
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An analog accumulator used in association with a solid state image analyzer for averaging and storing the fixed pattern noise (FPN) includes an N-stage transfer shift register with an input receiving a signal corresponding to the fixed pattern noise and with N outputs, N floating storage diodes each connected to an output of the transfer shift register, N reading parts each connected to a floating storage diode and each comprising a floating input diode connected to the floating storage diode through an injection gate, an injection device and a charge removal drain, and an N-stage transfer shift register with N inputs each connected to a reading part and with an output. The accumulator provides M integrations of N samples of an analog signal and delivers, at the end of the M integrations, the N accumulated samples several times.
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FIELD OF THE INVENTION
[0001] The invention relates to the manufacture of thermal break sections for the use in the manufacture of window, door, skylight frame assemblies and other fenestration related assemblies.
BACKGROUND OF THE INVENTION
[0002] Elongate metal sections for use in the manufacture of window and door frame assemblies are commonly extruded from aluminum. As is well known, it is often desirable for the interior and exterior parts of the section to be thermally isolated from one another. This thermal isolation prevents the low temperature of the exterior parts being transmitted to the interior parts and resulting in undesirable condensation on the internal surfaces. To this end it is common practice to provide a thermal break by connecting the interior and exterior parts of the section only by means of a nonmetallic connector of low thermal conductivity.
[0003] Following are two examples of methods used for providing such a thermal break. In a first method the section is formed from two separately preformed metal extrusions. These are connected together by preformed rigid non-metallic strips which are designed to interlock with the two metal extrusions respectively. Two non-metallic strips are often provided in spaced relation so as to form, with the metal extrusions, a hollow box section. There is then injected into this hollow box section a settable liquid plastics material, the setting of which forces the non-metallic strips and metal extrusions into rigid fixed relation.
[0004] A second common method of manufacturing a section with a thermal break is by the method known as “pour and cut”. According to this method the section is initially extruded and shaped to define an upwardly facing open channel. The channel is then filled with a settable liquid of low thermal conductivity, usually a plastics resin, which is then allowed to set. The part of the section forming the bottom of the channel is then cut through or debridged longitudinally, usually by a product from Azon USA, Inc. sold under the trademark “Bridgemill HMI”. If necessary, any other parts of the section connecting the interior and exterior parts thereof are also debridged so that the interior and exterior parts remain connected solely by the solidified resin, which thus provides the thermal break.
SUMMARY OF THE INVENTION
[0005] According to the invention, an architectural thermal barrier component and method of forming same includes an elongate section incorporating a thermal break, for example for use in the manufacture of window or door frame assemblies. The method comprises forming multiple co-extensive elongate elements, one of which includes a channel portion, aligning the elongate elements with one another, crimping the elements in engagement with one another, filling the channel with a settable liquid of low thermal conductivity, effecting solidification of the settable liquid to form a solidified thermal barrier element, and cutting longitudinally through or debridging any part of the elongate elements that bridges the thermal barrier element.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The following is a more detailed description of an embodiment of the invention, by way of example, reference being made to the accompanying drawings in which:
[0007] FIG. 1 is a cross-sectional view of two metal extrusions according to the invention.
[0008] FIG. 1A is an enlarged cross-sectional view of a portion of the two metal extrusions according to FIG. 1 .
[0009] FIG. 2 is a cross-sectional view of a port of the two metal extrusions of FIG. 1 in an engaged and unlocked condition.
[0010] FIG. 2A is an enlarged cross-sectional view of a portion of the two metal extrusions according to FIG. 2 .
[0011] FIG. 3 is a cross-sectional view of the two metal extrusions of FIGS. 1-2 in an engaged and locked or crimped condition.
[0012] FIG. 3A is an enlarged cross-sectional view of a portion of the two metal extrusions according to FIG. 3 .
[0013] FIG. 4 is a cross-sectional view of the two metal extrusions of FIGS. 1-3 after a settable resin has been placed.
[0014] FIG. 5 is a cross-sectional view of the two metal extrusions of FIGS. 1-4 after a portion of one of the metal extrusions has been cut away or debridged.
[0015] FIG. 6 is a cross-sectional view of metal extrusions for use in the method according to a further embodiment of the invention.
[0016] FIG. 7 is a cross-sectional view of the metal extrusions of FIG. 6 in an engaged and locked condition.
[0017] FIG. 8 is a cross-sectional view of the metal extrusions of FIGS. 6-7 after a settable resin has been placed and a portion of one of the extrusions has been cut away or debridged.
DETAILED DESCRIPTION
[0018] Certain terminology will be used in the following description for convenience and reference only, and will not be limiting. For example, the words “upwardly”, “downwardly”, “rightwardly” and “leftwardly” will refer to directions in the drawings to which reference is made. The words “inwardly” and “outwardly” will refer to directions toward and away from, respectively, the geometric center of the arrangement and designated parts thereof. Said terminology will include the words specifically mentioned, derivatives thereof, and words of similar import.
[0019] Referring to FIG. 1 , an architectural thermal barrier component such as a window or door frame assembly 10 includes exterior and interior architectural elements 15 , 20 extruded from a heat-conducting material, such aluminum or other metals. The elements 15 , 20 are configured for assembly and receipt of a material with low thermal conductivity to form a thermal break in the window frame assembly 10 .
[0020] As shown in FIGS. 1-5 , the exterior element 15 includes a planar portion 25 which has a flat outer surface 30 providing a visible exterior surface of the window frame assembly 10 . A box construction 35 projects from an inner surface 40 of the planar portion 25 and includes an upper side 45 and a lower side 50 . The upper and lower sides 45 , 50 are joined at an inner end 55 of the box construction 35 by a transverse flange 60 . The upper and lower sides 45 , 50 taper inwardly toward each other at their inner ends 65 , 70 so that respective upper and lower recesses 75 , 80 are formed between the upper and lower sides 45 , 50 and the transverse flange 60 . The upper side 45 further includes an internal screw channel 85 to aid in assembling the window frame assembly 10 , as is known in the art.
[0021] The interior element 20 includes a planar portion 90 which has a flat outer surface 95 providing a visible interior surface of the window frame assembly 10 . A box construction 100 projects from an inner surface 105 of the planar portion 90 and includes an upper side 110 and a lower side 115 . The upper and lower sides 110 , 115 are joined at an inner end 120 of the box construction 100 by an inner side 125 . The upper side 110 further includes an internal screw channel 130 to aid in assembling the window frame assembly 10 , as is known in the art.
[0022] The interior element 20 further includes a channel portion 135 extending from the inner side 125 of the box construction 100 . The channel portion 135 includes a channel floor section 140 extending inwardly, generally perpendicular to the inner side 125 , proximate the lower side 115 of the box construction 100 . A left channel side 145 extends upwardly from a left end 150 of the channel floor section 140 . A flange 155 extends from an upper end 160 of the inner side 125 , and a corresponding flange 165 extends from an upper end 170 of the left channel side 145 . Each of the flanges 155 , 165 includes a depending end portion 175 , 180 respectively. Projections 185 , 190 arise from the channel floor section 140 , aligned with the depending end portions 175 , 180 . Guide notches 192 , 193 are provided on a lower surface 194 of the channel floor section 140 inwardly of the projections 185 , 190 .
[0023] Upper and lower projections in the form of hooks 195 , 200 extend from the left channel side 145 . The upper hook 195 extends leftwardly from the upper end 170 of the left channel side 145 , and includes an inwardly directed barb 205 . The lower hook 200 extends leftwardly from a lower end 210 of the left channel side 145 and includes an inwardly directed barb 215 .
Method of Assembly
[0024] As shown in FIGS. 1 and 1A , the interior and exterior elements 15 , 20 are positioned ready for, but prior to, assembly. In FIGS. 2 and 2A , the elements 15 , 20 have been brought together such that the flange 60 is close against the left channel side 145 . During the initial assembly necessary to reach the condition shown in FIGS. 2 and 2A , the flange 60 must pass between hooks 195 , 200 or, more specifically, barbs 205 , 215 . The flange 60 is, however, wider than the distance between the barbs 205 , 215 .
[0025] One method of passing the flange 60 between the hooks 195 , 200 is to move the elements 15 , 20 laterally into engagement. As the elements 15 , 20 move together, the hooks 195 , 200 will contact the flange 60 . As the flange 60 passes between the barbs 205 , 215 , the hooks 195 , 200 will flex slightly until the barbs 205 , 215 clear the flange 60 . As the barbs 205 , 215 clear the flange 60 , there will be an audible and tactile “click” indicating to an assembler that the elements 15 , 20 are in the initial assembled position.
[0026] Another method of passing the flange 60 between the hooks 195 , 200 is to arrange the interior and exterior elements 15 , 20 substantially end to end, aligning the hooks 195 , 200 with the recesses 75 , 80 . The elements 15 , 20 are then moved longitudinally to a side by side configuration as the hooks 195 , 200 slide longitudinally into the recesses 75 , 80 .
[0027] Once assembled by either method, the upper hook 195 is aligned with the upper recess 75 and the lower hook 200 is aligned with the lower recess 80 . The upper and lower hooks 195 , 200 are splayed slightly outwardly from the recesses 75 , 80 so that they are not firmly engaged within the recesses 75 , 80 . However, a sufficient portion of the upper and lower hooks 195 , 200 are received into the recesses 75 , 80 to effect a holding together of the exterior element 15 and the interior element 20 to enable the assembler to easily handle the loosely connected together parts during a furtherance of the processing and without the elements 15 , 20 becoming easily disconnected. Since a two color scheme is to be employed, which color was applied to the exterior elements 15 and the interior elements 20 prior to the implementation of the loose connection therebetween, the thickness of the color coating on the exterior and interior elements 15 , 20 will not impact or negate the loose connection described above.
[0028] Referring to FIGS. 3 and 3A , the hooks 195 , 200 have been locked or crimped into the recesses 75 , 80 . The interior element 20 is thereby locked onto the exterior element 15 by the hooks 195 , 200 engaging the recesses 75 , 80 and specifically the barbs 205 , 215 engaging a back surface of the flange 60 . This locking or crimping will effect the required fixed locking of the exterior and interior elements 15 , 20 together so that the elements 15 , 20 cannot move with respect to one another. This fixed locking will occur independent of the respective thicknesses of the color coating on the exterior and interior elements 15 , 20 . That is, the crimping will impart a plastic deformation of the material of the color coating so that a metal to metal connection will exist without the material of the color coating coming between the elements 15 , 20 and negatively impacting the integrity or longevity of the connection.
[0029] Referring to FIG. 4 , the next step of forming the window or door frame assembly 10 is the application of a thermal barrier material 220 , such as poured polyurethane or other plastic or composite material having a low thermal conductivity. Examples of such materials are the “su” (structural urethane) series of thermal barrier chemicals, produced by Azon USA, Inc. of Kalamazoo, Mich. In order to fill the channel portion 135 , the combined section is fed into a conventional “pour and cut” machine (not shown). The construction and operation of such machines is well known and will not therefore be described in detail. The thermal barrier material 220 is applied to fill the channel portion 135 . As the thermal barrier material 220 cures and solidifies, it is physically engaged by the depending end portions 175 , 180 of the flanges 155 , 165 and the projections 185 , 190 of the channel floor section 140 .
[0030] After the thermal barrier material 220 has cured, a circular saw or other cutting implement (not shown) integral in the “pour and cut” machine is traversed longitudinally of the assembly 10 so as to cut through or debridge the channel floor section 140 between the notches 192 , 193 and between the projections 185 , 190 . The mechanical connection between the thermal barrier material 220 and the elements 15 , 20 is thereby undisturbed as the projections 185 , 190 remain intact and embedded in the thermal barrier material 220 . The assembly 10 thereby remains mechanically connected, but the “debridging” of the channel floor section 140 creates a thermal break between the exterior and interior elements 15 , 20 . The only thermal connection between the elements 15 , 20 is now through the thermal barrier material 220 , which has low thermal conductivity.
ALTERNATE EMBODIMENT
[0031] In a further embodiment of the invention, shown in FIGS. 6-8 , a window frame assembly 230 for including a thermal break includes exterior and interior architectural elements 235 , 240 and a connecting element 245 . The exterior element 235 is formed in similar fashion to the exterior element 15 of the first embodiment above. The exterior element 235 includes a planar portion 250 which has a flat outer surface 255 providing a visible exterior surface of the window frame assembly 230 . A box construction 260 projects from an inner surface 265 of the planar portion 250 and includes an upper side 270 and a lower side 275 . The upper and lower sides 270 , 275 are joined at an inner end 280 of the box construction 260 by a transverse flange 285 . The upper and lower sides 270 , 275 taper inwardly toward each other at their inner ends 290 , 295 so that respective upper and lower recesses 300 , 305 are formed between the upper and lower sides 270 , 275 and the transverse flange 285 . The upper side 270 further includes an internal screw channel 310 to aid in assembling the window frame assembly 230 , as is known in the art.
[0032] The interior element 240 includes a planar portion 315 which has a flat outer surface 320 providing a visible interior surface of the window frame assembly 230 . The remainder of the interior element 240 is formed similar to the exterior element 235 . A box construction 325 projects from an inner surface 330 of the planar portion 315 and includes an upper side 335 and a lower side 340 . The upper and lower sides 335 , 340 are joined at an inner end 345 of the box construction 325 by a transverse flange 350 . The upper and lower sides 335 , 340 taper inwardly toward each other at their inner ends 355 , 360 so that respective upper and lower recesses 365 , 370 are formed between the upper and lower sides 335 , 340 and the transverse flange 350 . The upper side 335 further includes an internal screw channel 375 to aid in assembling the window frame assembly 230 , as is known in the art.
[0033] The connecting element 245 includes a channel portion 380 . The channel portion 380 is formed by a channel floor section 385 and a pair of opposing, upright left and right channel walls 390 , 395 . A flange 400 , 405 extends inwardly from an upper end 410 , 415 of each of the channel walls 390 , 395 . Each of the flanges 400 , 405 includes a depending end portion 430 , 435 respectively. Projections 440 , 445 arise from the channel floor section 385 , aligned with the depending end portions 430 , 435 . Guide notches 450 , 455 are provided on a lower surface 460 of the channel floor section 385 inwardly of the projections 440 , 445 .
[0034] Upper and lower hooks 465 , 470 extend outwardly from the left channel wall 390 . The upper hook 465 extends outwardly from the upper end 410 of the left channel wall 390 , and includes an inwardly directed barb 475 . The lower hook 470 extends outwardly from a lower end 480 of the left channel wall 390 and includes an inwardly directed barb 485 . In like manner, upper and lower hooks 490 , 495 extend outwardly from the right channel wall 395 . The upper hook 490 extends outwardly from the upper end 415 of the right channel wall 395 , and includes an inwardly directed barb 500 . The lower hook 495 extends outwardly from a lower end 505 of the right channel wall 395 and includes an inwardly directed barb 510 .
[0035] In much the same fashion as the first embodiment, the window frame assembly 230 is assembled by drawing together the exterior and interior elements 235 , 240 . In the instant embodiment, however, the connecting element 245 is placed between the exterior and interior elements 235 , 240 such that the flanges 285 , 350 are close against the left and right channel walls 390 , 395 respectively. The audible and tactile “click” will indicate to the assembler that each of the exterior and interior elements 235 , 240 has engaged the connecting element 245 . The elements 235 , 240 , 245 can also be initially assembled by longitudinal sliding, as in the first embodiment. In this arrangement, the upper hook 465 is aligned with the upper recess 300 of the exterior element 235 and the lower hook 470 is aligned with the lower recess 305 of the exterior element 235 . Likewise, the upper hook 490 is aligned with the upper recess 365 of the interior element 240 and the lower hook 495 is aligned with the lower recess 370 of the interior element 240 .
[0036] The upper and lower hooks 465 , 470 , 490 , 495 are, however, splayed slightly outwardly from the recesses 300 , 305 , 365 , 370 so that they are not firmly engaged. As in the above embodiment, the hooks 465 , 470 , 490 , 495 are locked or crimped into the recesses 300 , 305 , 365 , 370 to lock the exterior and interior elements 235 , 240 onto the connecting element 245 , as shown in FIG. 7 .
[0037] The next step of forming the window or door frame assembly 230 with thermal break section is the application of a thermal barrier material 515 such as poured polyurethane or other plastic or composite material having a low thermal conductivity. The combined section is fed into a conventional “pour and cut” machine (not shown). The construction and operation of such machines is well known and will not therefore be described in detail. The thermal barrier material 515 is applied to fill the channel portion 380 . As the thermal barrier material 515 cures and solidifies, it is physically engaged by the depending end portions 430 , 435 of the flanges 400 , 405 and the projections 440 , 445 of the channel floor section 385 .
[0038] After the thermal barrier material 515 has cured, a circular saw or other cutting implement (not shown) integral in the “pour and cut” machine is traversed longitudinally of the assembly 230 so as to cut through or debridge the channel floor section 385 between the notches 450 , 455 and between the projections 440 , 445 . The mechanical connection between the thermal barrier material 515 and the separated left and right walls 390 , 395 of the channel portion 380 is thereby undisturbed as the projections 440 , 445 remain intact and embedded in the thermal barrier material 515 , as shown in FIG. 8 . The assembly 230 thereby remains mechanically connected, but the “debridging” of the channel floor section 385 creates a thermal break between the exterior and interior elements 235 , 240 . The only thermal connection between the elements 235 , 240 is now through the thermal barrier material 515 , which has low thermal conductivity.
[0039] The arrangements described above have the advantage that the elements 15 , 20 , 235 , 240 can be extruded consistently with the required tolerances using conventional extrusion technology. The “pour and cut” apparatus can have a conventional configuration and can be used in the conventional manner when the combined section has been assembled.
[0040] The pre-coloring of the elements may be carried out by any of the commonly used methods. The detailed dimensions of the inter-engaging parts of the elements may be so selected as to allow for the thickness of the colored coating and the lesser hardness of the coating may be employed to compensate for tolerances in the dimensions of the inter-engaging parts.
[0041] While the invention has been described in the specification and illustrated in the drawings with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention as defined in the claims. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment illustrated by the drawings and described in the specification as the best mode presently contemplated for carrying out this invention, but that the invention will include any embodiments falling within the scope of the appended claims.
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According to the invention, an architectural thermal barrier component and method of forming same includes an elongate section incorporating a thermal break, for example for use in the manufacture of window, door, skylight frame assemblies and other fenestration related assemblies. The method comprises forming multiple co-extensive elongate elements, one of which includes a channel portion, and aligning the elongate elements with one another by snap-fitting the elements together or sliding the elements together longitudinally. After the initial assembly, the method includes crimping the elements in engagement with one another, filling the channel with a settable liquid of low thermal conductivity, effecting solidification of the settable liquid to form a solidified thermal barrier element, and cutting longitudinally through or debridging any part of the elongate elements that bridges the thermal barrier element.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a biaxially oriented container formed of a thermoplastic resin containing glass fibers.
2. Description of the Prior Art
Containers biaxially oriented by stretch blow molding thermoplastic resins such as polyethyleneterephthalate resin, polyvinyl chloride, etc. are excellent in gas barrier properties and mechanical strength as compared with containers obtained by blow molding and have a wide application not only for beverages but foods, cosmetics, medicines, etc.
Particularly, biaxially oriented containers formed of polyethyleneterephthalate resin increase in demand year after year but are low in glass transition point similarly to vinyl chloride resin. Even if the mechanical strength of containers is materially increased by biaxial orientation, there is a limitation in heat resisting property. In the case where the container is used as a container for contents whose filling temperature is above 70° C., is has been necessary to impart the heat resisting property thereto by some means. When the container is used as a container for contents having pressure such as carbonated beverages even if the contents are low in filling temperature, there poses problems in that a bottom of a container is deformed due to an increase in internal pressure resulting from elevation of temperature not only to lose a self-supporting property as a bottle but result in explosion due to the shock at the time of falling.
As a means for solving these problems noted above with respect to the biaxially oriented containers, there has been employed a method for heating a stretch blow molded container at a higher temperature than the glass transition point to stabilize it against heat. Even by such a method, the heat resisting property is merely improved for a temperature in the vicinity of glass transition point but the durability for a higher temperature than the firstmentioned temperature and pressure under the high atmospheric temperature.
According to another approach, glass fiber is mixed into polyethyleneterephthalate resin in an attempt of enhancing the heat resisting property and the pressure resisting and further the gas barrier property and the like by said glass fiber. However, the moldability resulting from stretch blow molding of thermoplastic resin containing glass fibers varies with the content of glass fibers. The more content, the better various properties are obtained but conversely stretch blow molding becomes difficult to perform.
Accordingly, even the content of glass fibers has a limitation for reason in terms of molding, and in the content within the moldable range, the gas barrier property can be enhanced to some extent but satisfactory heat resisting property and pressure resisting property may not be obtained.
SUMMARY OF THE INVENTION
In view of the foregoing, the present inventor has found a new biaxially oriented container containing glass fibers as the result of repeated studies on biaxially oriented containers formed of thermoplastic resin excellent in heat resisting property and pressure resisting property, even if the content of glass fibers is within the range capable of performing stretch blow molding, particularly containers formed of polyethyleneterephthalate resin, vinyl chloride resin, etc.
It is an object of this invention to provide a biaxially oriented container which can be very easily molded by extrusion or injection stretch blow molding heretofore used and which exhibits satisfactory heat resisting property and pressure resisting property even if the content of glass fibers is less than 10 weight %.
It is a further object of the invention to provide a biaxially oriented container excellent in heat resisting property and pressure resisting property which can be used widely as containers for beverages and foods, and carbonated beverages which require heating and filling, and as containers for cosmetics, medicines, liquers, etc. and which can sufficiently withstand internal pressure even under high atmospheric temperature to maintain a self-supporting property and not being attended by explosion.
The present invention having the above-described objects provides a container formed by biaxially orienting a thermoplastic resin containing glass fibers to a value more than 3 of area stretching magnification, said container having said glass fibers of 0.3 to 10 weight % and being thermally fixed in the range of temperature from 70° to 180° C.
Glass fibers that may be used for the present invention have a fiber diameter of 5 to 20μ, and a fiber length of 1 to 6 m/m, preferably, have the ratio of length to diameter in the range from 200 to 300, which can be fine particles of glass as the case may be.
The content of glass fibers to resins is 0.3 to 10 weight %, preferably 1.5 to 4 weight %, but said content varies with the shape and use of containers to be molded. However, if the content of glass fibers is less than 0.3 weight %, the strengthening effect by the glass fibers may not be achieved, and if the content exceeds 10 weight %, it becomes extremely difficult to effect molding by a normal stretch blow molding method.
A biaxially oriented container in accordance with the present invention may be molded by axially stretching a preliminary molded body extruded or injection molded before hand at a temperature in the vicinity of glass transition point, and blowing air therein to expand it fully in the cavity.
Glass fibers are contained in resins by when a preliminary molded body is formed, evenly adding a predetermined quantity thereof to the resins and mixing them with the resins within an extruding or injecting heating cylinder, or preparing a master batch of high content to mix the master batch with the resin in a predetermined ratio and containing them in the resins.
Preferably, processes from molding of said preliminary molded body to molding of a biaxially oriented container having a value of more than 3 of area stretching magnification (product of longitudinal stretching and lateral stretching) are continuously carried out. Molding is possible to make even by a cold parison system in which a preliminary molded body cooled to a room temperature is again heated to a glass transition temperature to stretch blow mold it. However, this molding method is difficult to make adjustment of temperature of a preliminary molded body at the time of stretch blow molding as compared with a hot parison system in which stretch blow molding is effected while maintaining a temperature of the preliminary molded body at a level in the vicinity of glass transition point.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Glass fibers having a fiber length of 3 m/m and a fiber diameter of 10μ in the amount of 2.2 weight % were added to polyethyleneterephthalate resin (TEIJIN, LTD., TR-8550), they were mixed with resins within an injection cylinder and thereafter the resins were injected into an injection mold to form a preliminary molded body having a bottom in which the glass fibers were evenly mixed.
This preliminary molded body has a weight of approximately 29 g with a neck integrally formed with a support ring. The preliminary molded body was released at a temperature as high as possible and immediately thereafter, the internal temperature was adjusted, and then it was stretch blow molded into a bottle of 500 ml having a value of more than 3 times of area stretching magnification within a blow mold heated to a temperature from 70° to 180° C. Simultaneously with molding, the container was heated by the blow mold for a predetermined period of time, and thereafter, it was released from the blow mold and a thermally fixed biaxially oriented container was removed.
In the thus molded biaxially oriented container, the resin present between the glass fibers gives rise to thermal shrinkage by the heating after molding and becomes stabilized against the temperature below the heating temperature. In addition, the resins were strengthened by the glass fibers to increase the buckling strength.
One example of the molding conditions is given below:
Machine used: ASB-50 (NISEEI ASB MACHINE CO., LTD.-made)
Temperature of injection cylinder: 270°-280° C.
Temperature of injection mold: 10°-12° C.
Temperature of preliminary molded body: 100° C.
Blow pressure (air): 14 Kg/cm 2
Blowing time: 12 sec.
Temperature of blow mold: 105° C.
It will be noted that a container can be thermally fixed by a blow medium without heating the blow mold, in which case the temperature of blow medium is set to 200° to 250° C. and blowing is maintained for 3 to 10 seconds.
Next, the performance of the biaxially oriented container in accordance with the present invention is shown as well as comparative examples.
__________________________________________________________________________ Pressure resisting strength bolt elon- Shrinking gation percentage (%) Content of Temperature percent of Outer doa. glass fiber of blow mold hot water Buckling Total Dia. of of support External (%) (°C.) (%) (Kg) height body ring appearance__________________________________________________________________________Embodiment 1 2.2 105 0.8 65.5 2.8 3.1 0.9 UnchangedEmbodiment 2 2.2 75 2.6 65.6 3.1 3.4 2.1 UnchangedComparative 2.2 25 3.4 65.6 3.6 3.6 6.3 Partlyexample 1 deformedComparative 0 25 25.4 47.5 6.0 8.9 21.7 Deformedexample 2__________________________________________________________________________
Shrinking Percentage of Hot Water
Hot water at 90° C. is filled in a bottle, and the content of the bottle after it has been left alone for 12 hours was measured.
Shrinking percentage=(V.sub.o -V/V.sub.o)×100%
where
V o : Volume of bottle before hot water is filled
V: Volume of bottle after hot water is filled.
Buckling Strength
A tension/compression testing machine TCM-500 of SHINKO TSUSHIN KOGYO CO., LTD.-made was used and a load was applied to an empty bottle vertically at a corss head speed of 500 mm/min. to obtain the maximum load when the bottle is deformed.
Pressure Resisting Strength (under high pressure)
A bottle filled with 3.6 Volume of CO 2 gas (or CO 2 7 g) was immersed in a 76° C. thermostatic oven for 20 minutes to check dimensions of parts and changes in external appearance. Gas pressure of 3.6 Volume at 76° C. is approximately 12-13 Kg/cm 2 . Elongating percentage of dimensions of parts was calculated by the following equation.
Elongating percentage=(A-A.sub.o /A.sub.o)×100
where
A o : Dimension prior to immersion into 76° C. thermostatic oven
A: Dimension obtained after leaving alone at a low temperature for 12 hours after immersion into 76° C. thermostatic oven.
As described above, the biaxially oriented container in accordance with the present invention possesses the advantages, which cannot be attained by prior art containers, that it is excellent in heat and pressure resisting properties and may be used as a container for contents to be filled at a high temperature and as a pressure container for carbonated beverages and the like which can withstand high atmospheric temperature.
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This invention provides a biaxially oriented container which can be very easily molded by extrusion or injection stretch blow molding and which exhibits satisfactory hat resisting property and pressure resisting property even if the content of glass fibers is less than 10 weight %.
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BACKGROUND
[0001] The present invention relates generally to methods and apparatus for connecting lengths of coiled tubing. More particularly, the present invention relates to spoolable coiled tubing connectors that maintain the pressure and tensile strength ratings of the tubing.
[0002] Conventional tubing strings are constructed in thirty foot long straight sections that are connected in series. A coiled tubing string generally includes a continuous length of small diameter tubing that is much more flexible than conventional tubing and can therefore be spooled onto a reel. The coiled tubing is unwound from the reel and directed over a gooseneck and through a tubing injector head into a wellbore. Coiled tubing is used for a variety of wellbore processes, including injecting gas or other fluids into the wellbore, inflating or activating bridge plugs and packers, transporting well logging tools downhole, performing remedial cementing and clean-out operations in the wellbore, and delivering or retrieving drilling tools downhole.
[0003] As the utilization of coiled tubing expands into applications involving greater depths, pressures, and more remote operating locations, the complexity and size of a coiled tubing system increase. Transportation and handling constraints often limit the size of the reel and the corresponding length of coiled tubing able to be stored on a given reel. To overcome this limitation, lengths of coiled tubing from multiple reels can be connected in series and used in a single operation. These multiple lengths can then be spooled back onto a single, larger reel for more efficient storage. Although lengths of coiled tubing can be welded together, welding requires special equipment, personnel, and a closely controlled environment. In connecting lengths of coiled tubing, a mechanical connector that does not require welding at a well site can simplify the connection process by enabling faster connections in a wider variety of environmental conditions.
[0004] In operation, coiled tubing is subjected to bending stresses both when being spooled onto and off of the reel and when being fed over the gooseneck into the injector head. A mechanical connector joining lengths of coiled tubing will also be subjected to these bending stresses. As the length and stiffness of a connector increase, areas of stress concentration will develop in the regions of the coiled tubing immediately adjacent to the connector. Therefore, it is desirable to minimize both the overall length and stiffness of a coiled tubing connector.
[0005] Thus, there remains a need to develop methods and apparatus for connecting lengths of coiled tubing, which overcome some of the foregoing difficulties while providing more advantageous overall results.
SUMMARY
[0006] Disclosed herein is a tubing connector comprising a rigid member having a first end and a second end, a crimping groove disposed about the rigid member, and a sleeve fixably attached to the rigid member and covering the crimping groove.
[0007] Further disclosed herein is a method for connecting a tubing section to a rigid member, the method comprising fixably attaching a sleeve over one end of the rigid member to cover a crimping groove disposed on the rigid member, disposing the tubing section over the sleeve, and plastically deforming the tubing section and sleeve to form a plurality of dimples in that project into the crimping groove of the rigid member.
[0008] Further disclosed herein is a spoolable tubing connector comprising a flexible tubing section having first and second ends, a first rigid member fixably attached to the first end of the flexible tubing member, the first rigid member comprising at least one crimping groove, a first sleeve fixably attached to the first rigid member, wherein the first sleeve covers the crimping groove on the first rigid member, a second rigid member fixably attached to the second end of the flexible tubing member, the second rigid member comprising at least one crimping groove, and a second sleeve fixably attached to the second rigid member, wherein the second sleeve covers the crimping groove on the second rigid member.
[0009] Thus, the present invention comprises a combination of features and advantages that enable it to overcome various problems of prior devices. The various characteristics described above, as well as other features, will be readily apparent to those skilled in the art upon reading the following detailed description of the following embodiments of the invention, and by referring to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] For a more detailed description of representative embodiments of the present invention, reference will now be made to the accompanying drawings, wherein:
[0011] FIG. 1 is a partial sectional view of a coiled tubing connector;
[0012] FIG. 2 is a partial sectional view of a coiled tubing connector engaged with a tubing section;
[0013] FIG. 3 is a partial sectional view of a double ended coiled tubing connector; and
[0014] FIG. 4 is a partial sectional view of a coiled tubing connector.
DETAILED DESCRIPTION
[0015] Referring now to FIG. 1 , a coiled tubing connector 10 is shown comprising a rigid member 12 , first tubing section 14 , sleeve 16 , and seal 20 . Rigid member 12 is a tubular member having an inner diameter defining an axial flow passage 13 and a maximum outer diameter 15 that is closely matched to the outside diameter of first tubing section 14 . The outside surface of rigid member 12 includes first tubing interface 21 , sleeve interface 23 , and second tubing interface 25 .
[0016] First tubing interface 21 includes first end 22 and first shoulder 24 , which is adjacent to maximum outer diameter 15 . First end 22 has a diameter sized so as to closely fit within first tubing section 14 . First end 22 is inserted into first tubing section 14 such that the end of the first tubing section 14 is disposed in close relation to first shoulder 24 , enabling weld 26 to be formed between rigid member 12 and first tubing section 14 . Weld 26 prohibits axial and radial movement of first tubing section 14 relative to rigid member 12 .
[0017] Sleeve interface 23 is on the opposite end of rigid member 12 from first tubing interface 21 . Sleeve interface 23 includes crimping groove 18 , second end 28 , and shoulder 19 . Sleeve interface 23 has a diameter sized so as to fit in close relationship with the interior of sleeve 16 . Second end 28 is inserted into sleeve 16 such that one end of the sleeve 16 is disposed in close relation to shoulder 19 , enabling weld 30 to be formed between rigid member 12 and sleeve 16 . Weld 30 prohibits axial and radial movement of sleeve 16 relative to rigid member 12 . Crimping groove 18 extends continuously, or discontinuously, around the perimeter of rigid member 12 and is positioned axially along rigid member 12 so that sleeve 16 covers the crimping groove 18 when the sleeve 16 is welded to the rigid member 12 .
[0018] Second tubing interface 25 is located between sleeve interface 23 and first tubing interface 21 and includes seal groove 32 and shoulder 34 . Second tubing interface 25 has an outer diameter approximately equal to the outer diameter of sleeve 16 . Second tubing interface 25 continues axially from shoulder 19 to shoulder 34 , where the diameter increases to maximum diameter 15 . The diameter of second tubing interface 25 is sized so as to fit within, and in close relationship with the inner diameter of, a second tubing section 36 , as shown in FIG. 2 .
[0019] Rigid member 12 is constructed from a material suitable for use with the coiled tubing string. Rigid member 12 may be constructed from metallic materials, such a steel, stainless steel, high-chrome steel, or other machinable, weldable material. The inside diameter of rigid member 12 , which forms flow passage 13 , may include sloped ends 40 where the diameter gradually increases in order to provide a smooth transition and eliminate any internal ledges. The overall length of rigid member 12 is minimized so as to reduce the stiffness of connector 10 . As the length of rigid member 12 increases, the stiffness of connector 10 and the stress developed in the coiled tubing string also increase.
[0020] Sleeve 16 is a relatively thin walled tubular member that is constructed from a material suitable for use with the coiled tubing string. Sleeve 16 has an outer diameter sized so as to fit in close relationship with the inner diameter of second tubing section 36 , as shown in FIG. 2 . The outside surface of sleeve 16 may have a longitudinal groove so as to accommodate a weld seam projecting from the inside surface of second tubing section 36 . End 42 of sleeve 16 may also be sloped so as to provide a smooth transition between the inner diameters of second tubing section 36 and rigid member 12 .
[0021] Sleeve 16 may be extended past the end of rigid member 12 in order to provide support to second tubing section 36 . As the coiled tubing string and connector 10 are spooled on a reel or run over a gooseneck, the bending stresses imparted on the coiled tubing string will tend to create stress concentrations in second tubing section 36 immediately adjacent to connector 10 . Sleeve 16 operates to decrease these stress concentrations and increase the useful life of the coiled tubing string.
[0022] Seal 20 is disposed within seal groove 32 positioned within second tubing interface 25 . As shown in FIG. 2 , seal 20 engages the inner wall of second tubing section 36 . Seal 20 is a static, permanent seal that may be constructed of any seal material that is compatible with the environments in which the coiled tubing string may be used. For example, seal 20 may be constructed from an elastomeric material, such as nitrile rubber, or a polymeric seal material, such as VITON™ or PEEK™. Seal 20 may include a combination of seal members and backup members as necessary to meet the sealing requirements of the system.
[0023] Referring now to FIG. 2 , connector 10 is shown engaged with a second tubing section 36 . Sleeve 16 and second end 28 are inserted into second tubing section 36 such that one end of the second tubing section 36 is adjacent to shoulder 34 . The outer diameter of second tubing section 36 closely matches the maximum outer diameter 15 of rigid member 12 and the outer diameter of first tubing section 14 , such that the outer diameter remains substantially constant across connector 10 .
[0024] A series of dimples 38 are formed in second tubing section 36 by applying a localized force to plastically deform second tubing section 36 and push a small area of the second tubing section 36 wall and sleeve 16 into engagement with crimping groove 18 . Dimples 38 may be formed by pins, or some other member, being pushed against second tubing section 36 by hydraulic or mechanical force. The pins may be axially located by a jig, or other structure, that can be temporarily attached to connector 10 so as to reliably align the pins with crimping groove 18 . Dimples 38 can be placed at any desired radial location on the perimeter of second tubing section 36 , and do not require radial alignment within crimping groove 18 . The number of dimples 38 required will depend on the size of connector 10 and the axial loads for which the coiled tubing string is rated.
[0025] Dimples 38 engage crimping groove 18 and prohibit axial movement of rigid member 12 relative to second tubing section 36 . Dimples 38 also prohibit axial and rotational movement of second tubing section 36 relative to sleeve 16 , which is connected to rigid member 12 by weld 30 . As discussed above, weld 30 prohibits axial and rotational movement of sleeve 16 relative to rigid member 12 . Therefore, second tubing section 36 is prohibited from axial and rotational movement relative to rigid member 12 . Axial and rotational movement of rigid member 12 relative to first tubing section 14 is prohibited by weld 26 . Therefore, axial and rotational movement of first tubing section 14 relative to second tubing section 36 is prohibited by rigid member 12 of connector 10 .
[0026] Referring now to FIG. 3 , a coiled tubing connector 44 is shown including two connectors 10 connected by a flexible tubing section 46 . Each connector 10 has a rigid member 12 with a corresponding sleeve 16 , crimping groove 18 , and seal 20 , as described previously. Connector 44 may be used to connect two lengths of coiled tubing to effectively create a longer string of tubing with the same pressure and tensile load characteristics of the component strings, without the need for welding at the job site.
[0027] Flexible tubing section 46 is constructed from a material having a diameter, length, and wall thickness selected so as to provide a desired amount of flexibility between rigid members 12 . This flexibility allows connector 44 to bend as the coiled tubing string is being spooled onto a reel or being run over the gooseneck. Flexible tubing section 46 may be a section of coiled tubing similar to the coiled tubing strings with which connector 44 will be employed. Alternatively, flexible tubing section 46 may be some other material selected for its flexibility and performance under repeated bending loads. In one embodiment, flexible tubing section 46 has an outside diameter no larger than the outside diameter of the coiled tubing string with which it is used.
[0028] FIG. 4 illustrates an alternate embodiment of a connector 48 including a rigid member 50 having multiple crimping grooves 52 and redundant seals 54 . Sleeve 56 covers each of crimping grooves 52 . Multiple crimping grooves 52 may be utilized in certain applications requiring connector 48 to withstand higher axial and rotational loads. Multiple seals 54 may be utilized in certain applications where sealing redundancy and reliability are especially valuable. The overall length of rigid member 50 is still minimized so as to reduce the stiffness of connector 48 .
[0029] Connectors for coiled tubing as described above may find use in many tubing applications. These types of connectors could be used to join two lengths of tubing or to provide end connectors for connecting the tubing to a bottom hole assembly, or some other component. Connectors such as those described could also find use in other tubing applications outside of coiled tubing.
[0030] While representative embodiments of this invention have been shown and described, modifications thereof can be made by one skilled in the art without departing from the scope or teaching of this invention. The embodiments described herein are exemplary only and are not limiting. Many variations and modifications of the system and apparatus are possible and are within the scope of the invention. For example, the relative dimensions of various parts, the materials from which the various parts are made, and other parameters can be varied, so long as the coiled tubing connector apparatus retain the advantages discussed herein. Accordingly, the scope of protection is not limited to the embodiments described herein, but is only limited by the claims that follow, the scope of which shall include all equivalents of the subject matter of the claims.
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A tubing connector comprising a rigid member having a first end and a second end; a crimping groove disposed about the rigid member; and a sleeve fixably attached to the rigid member and covering the crimping groove. A method for connecting a tubing section to a rigid member, the method comprising fixably attaching a sleeve over one end of the rigid member to cover a crimping groove disposed on the rigid member, disposing the tubing section over the sleeve, and plastically deforming the tubing section and sleeve to form a plurality of dimples that project into the crimping groove of the rigid member.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a national phase entry under 35 U.S.C. §371 of international Patent Application PCT/EP2010/065311 filed on Oct. 13, 2010, published in English as International Patent Publication No. WO 2011/045333, which claims the benefit under Article 8 of the Patent Cooperation Treaty to European Patent Application Serial No. 09173040.8, filed Oct. 14, 2009.
TECHNICAL FIELD
[0002] The present invention relates to a method to control spider mites on plants. More specifically, the invention relates to plants, expressing RNAi of one or more essential genes of the spider mite, and the use of those plants to control the spider mite proliferation into pest proportions. In a preferred embodiment, the spider mite is Tetranychus urticae.
BACKGROUND
[0003] Spider mites are arthropods, belonging to the subphylum of chelicerates (scorpions, horseshoe crabs, spiders, mites and ticks). The mites include different species that can be parasitic on vertebrate and invertebrate hosts, predators, or plant feeding. Within the mites, the spider mites group the web-spinning species that feed on plants.
[0004] Spider mites, and particularly T. urticae (two-spotted spider mite) is one of the major pests in agriculture. It is extremely polyphagous and feed on over 1000 plant species. Moreover, it shows a rapid development (generation time of seven days in a hot season). T. urticae represent a key pest for greenhouse crops, annual field crops and many horticultural crops, such as peppers, tomatoes, potatoes, beans, corn, strawberries and roses. It is widespread all over the world, and occurs freely in nature in regions with a warm and dry climate.
[0005] Spider mites cause yellow flecks on the leaf surface, and upon heavy infestation, leaves become pale, brittle and covered in webbing. This damage can cause severe reduction in yield.
[0006] Spider mites are particularly important pests for vegetables. Spider mites cause significant damage to greenhouse tomato, cucumber and pepper crops.
[0007] Given the short generation time and high reproduction rate of spider mites, it is expected that spider mites, with the climate change, will become one of the major pests for crops as well. Devastating effects of spider mites are already creating enormous problems for the agricultural production in Southern Europe.
[0008] Spider mite control, currently, is mainly done by specific miticides, as normal insecticides have normally little effect on mites. Miticides have been disclosed, amongst others, in WO03014048 and in WO2007000098. However, miticides are polluting chemicals, and the application may not always be efficient, as spider mites are often protected by a web under the leaves.
[0009] Recently, the RNA interference (RNAi) technology was developed as an attractive alternative in the control of insect pests (Gordon and Waterhouse, 2007; Baum et al., 2007; Mao et al., 2007). RNAi is based on sequence-specific gene silencing that is triggered by the presence of double-stranded RNA (dsRNA). RNAi can be used in plants, animals and insects, but the mechanism depends upon endogenous enzymes present and the efficacy depends upon the host organism used (Gordon and Waterhouse, 2007). Khila and Grbic (2007) demonstrated that dsRNA and short interfering RNA (siRNA) can be used for gene silencing in T. urticae , by using a maternal injection protocol to deliver interfering RNAs into the maternal abdomen. This methodology has been used to silence Distal-less, a conserved gene involved in appendage specification in metazoans.
[0010] However, gene silencing has never been used in pest control for spider mites. One reason is the uncertainty whether RNAi, supplied in the food, would be functional. Another reason is the lack of sequence data of spider mites, making a selection of mite-specific genes that are lethal when knocked out by RNAi impossible.
DISCLOSURE
[0011] We sequenced and annotated the genome of T. urticae . This effort allowed us to pinpoint a set of essential mite-specific genes without relevant plant or mammalian orthologs. From these sequences, RNAi loops were designed that were specific for one essential mite gene, without interfering with the expression in plants or in mammals. Surprisingly, we found that expressing RNAi in a plant derived from those genes, is sufficient to interfere with the spider mite's development and physiology that is feeding on this plant, resulting in death as a consequence.
[0012] A first aspect of the invention is a transgenic plant expressing RNAi derived from a spider mite. Preferably, RNAi is derived from an essential gene of the spider mite. Even more preferably, the RNAi is derived from a gene-specific region (GSR) of the essential genes. A “transgenic plant” can be any plant that is, as wild-type, sensitive to spider mite infection, including, but not limited to, members of the citrus family (lemon, oranges, . . . ), grapefruit, different varieties of Vitis , corn, as well as Solanaceae like tomatoes, cucumber, . . . and ornamental flowers. “Derived” as used here, means that the gene region that is transcribed (including the non-coding regions) is used to design the RNAi; preferably, the RNAi comprises an antisense fragment of the transcribed region. Even more preferably, it consists of an antisense region of the transcribed region. The RNAi comprises only a part of the transcribed mRNA. A “GSR” is a gene region without homology with other mite genes and without homology with the host genome, as determined according to Example 1. A GSR allows the design of RNAi that is specific for the target gene, without interfering with other mite genes or with plant or mammalian genes. An “essential gene” as used here means that the inactivation of the gene is blocking growth and/or development of the mite and may result in the death of the mite. Preferably, the essential gene is selected from the group consisting of GABA receptor gene, stem cell gene, neutralized gene, HOX gene, DEV gene, Cytochrome C gene, Hedgehog gene, NADH dehydrogenase gene, Ryanoid receptor gene, sodium channel gene, acetylcholine esterase gene, son of sevenless gene, prospero gene, acetyl choline receptor gene and distal-less gene (Dll). Preferably, the spider mite is T. urticae . In one preferred embodiment, the RNAi is derived from the T. urticae distal-less gene (RNAi indicated as Tetur17g02200-SEQ ID NO:86); preferably, it is comprising the sequence between the primers as shown in FIG. 1 . In another preferred embodiment, the RNAi is comprising a sequence selected from the group consisting of SEQ ID NOS:1-87. Even more preferred, the RNAi is comprising a sequence; even more preferably, consisting of a sequence selected from the group consisting of SEQ ID NOS:1, 2, 4, 6, 9, 14, 18, 20, 21, 22, 24, 33, 34, 35, 36, 37, 38, 39, 46, 49, 50, 63, 75, 86 and 87. Most preferably, the RNAi is comprising a sequence; even more preferably, consisting of a sequence selected from the group consisting of SEQ ID NOS:2, 18, 22, 75 and 86.
[0013] Although, preferably, the inactivation of the mites is obtained by expressing a single RNAi species, it is clear for the person skilled in the art that the same effect may be obtained by expressing more than one RNAi species, in order to obtain a stronger inhibition.
[0014] Another aspect of the invention is a method to improve mite resistance in plants, comprising the expression of RNAi derived from spider mite. Preferably; the RNAi is derived from an essential gene from spider mite; even more preferably, the RNAi is derived from a gene-specific region (GSR) of the essential gene. Preferably, the essential gene is selected from the group consisting of GABA receptor gene, stem cell gene, neutralized gene, HOX gene, DEV gene, Cytochrome C gene, Hedgehog gene, NADH dehydrogenase gene, Ryanoid receptor gene, sodium channel gene, acetylcholine esterase gene, son of sevenless gene, prospero gene, acetyl choline receptor and distal-less gene (Dll). Preferably, the spider mite is T. urticae . In one preferred embodiment, the RNAi is derived from the T. urticae distal-less gene; preferably it is comprising the sequence between the primers as shown in FIG. 1 . In another preferred embodiment, the RNAi is derived from a sequence comprising a sequence selected from the group consisting of SEQ ID NOS:1-87. Even more preferred, the RNAi is comprising a sequence; even more preferably, consisting of a sequence selected from the group consisting of SEQ ID NOS:1, 2, 4, 6, 9, 14, 18, 20, 21, 22, 24, 33, 34, 35, 36, 37, 38, 39, 46, 49, 50, 63, 75, 86 and 87. Most preferably, the RNAi is comprising a sequence; even more preferably, consisting of a sequence selected from the group consisting of SEQ ID NOS:2, 18, 22, 75 and 86.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 : Sequence of the Tetranychus urticae distal-less gene (Dll) (SEQ ID NO:264) and the primers used (TuDII_ARBF and TuDII_ARBR) (SEQ ID NO:265 and 266, respectively). The primer regions in the distal-less sequence are underlined. The fragment in between the primers is used in the RNAi construct. The amino acid sequence is identified as SEQ ID NO:268.
[0016] FIG. 2 : Construct used to express TuDll-RNAi transgene in Arabidopsis.
[0017] FIG. 3 : Arabidopsis plants expressing dsRNA against Tu-D11 suppress mite development. A) Northern blot analysis showing siRNAs against TuDll spider mite gene; Col is a control, not expressing the transgene. B) Effect of plant-produced TuDll-RNAi (Lines 1-5) on spider mite development. Note that number of eggs deposited on transgenic plants is lower than in the Col control. Also, the number of eggs correlates with the amount of TuDll-RNAi expressed.
[0018] FIG. 4 : Plasmid map of pB-AGRIKOLA-Tetur17g02200.
DETAILED DESCRIPTION OF THE INVENTION
Examples
Example 1
Growth Inhibition of T. urticae by Feeding on TuDll-RNAi Transgenic Arabidopsis
[0019] The T. urticae ortholog of the drosophila Dll distal-less gene was identified in the genomic sequence, using the motifs of the distal-less family (Fonseca et al., 2009). Distal-less is a transcription factor that plays an important role in neuronal development (Cobos et al., 2005). An RNAi fragment is designed on the base of its specificity (no significant homology with other T. urticae genes, neither with the Arabidopsis genome). The RNAi fragment, as well as the primers used to isolate it, is shown in FIG. 1 . The fragment was amplified, and cloned under control of the CaMV 35S promoter, to result in the Ti-based plasmid pFGC5941 ( FIG. 2 ). The plasmid was transformed using the Agrobacterium -mediated transformation into Arabidopsis thaliana (Col). The expression of the RNAi in different transformed lines was tested by Northern blot ( FIG. 3 , Panel A). Spider mites were allowed to feed on five transformed lines and a control plant. All transformed plants showed an inhibition of mite development, both of the moving stages and the number of eggs on the plant. A correlation between the expression level of RNAi and the number of eggs on the transgenic plants was found ( FIG. 3 , Panel B), proving that the expression in plants of RNAi of an essential spider mite gene is indeed an efficient way to control the pest.
Example 2
RNAi Design for Other Essential Genes
[0020] From a list of candidate Tetranychus urticae target genes, coding sequences (CDS, from start-to-stop codons) were collected from the available predicted genes. For each of those genes, overlapping 21mer sequences were designed covering the whole CDS sequences. This was done by extracting, starting from the first nucleotide of the CDS, sub-sequences of 21 nt, with a sliding window, with steps of one nt. For each CDS from the target genes, n−20 oligos of 21 nt were designed, whereby n is the length of the CDS.
[0021] Each of these 21mers was blasted (using BLASTN) against the whole Tetranychus urticae genome. In the case of a perfect match, an e-value of 1e−4 is obtained. To allow some mismatch the threshold was set at 0.01. The threshold was lowered to ensure that no 21mer would hit another region on the genome with a small sequence difference of 1 or 2 nt, thereby ensuring the gene specificity for the RNAi.
[0022] Gene-specific regions (GSR), ideally being between 150 and 500 nt, were identified as regions for which, over the whole region, none of the consecutive 21mers derived from this region gave a hit with another sequence from the T. urticae (using the threshold as described above).
[0023] The GSR that did meet the above conditions were subsequently blasted (BLASTN, same thresholds) against the Arabidopsis genome. Arabidopsis was chosen, as it is used as host in the proof of principle experiments. This step is to make sure that no Arabidopsis genes could be targeted by the RNAi constructs introduced and that might thus affect Arabidopsis directly; GSR can be blasted against other genomes for optimizing the RNAi in other plant hosts.
[0024] All GSR that fulfilled the above criteria (SEQ ID NOS:1-85) were then used as input for primer design. The primers where designed using the OSP perl package, and as a parameter, the melting temperature was set at the 55° C. to 65° C. range in a first run (Table 1). Those targeted GSR that did not succeed in obtaining a primer pair were submitted again to the same design procedure, with slightly more relaxed primer lengths allowed (Table 2). If, with those conditions, still no primers could be designed, melting temperature range was relaxed (50° C. to 70° C.) for a third attempt (Table 3).
[0000]
TABLE 1
primers designed after 1 run
SEQ_ID
5_PRIMER
3_PRIMER
0_197_
ATAAAATCTCCAAGCATAGTACGAGTT (SEQ ID NO: 88)
TTAACCACAGTCACTCGACCTTCA (SEQ ID NO: 89)
Tetur41g00290
0_228_
No Primers could be designed with these
Tetur30g02230
criteria
1066_1216_
TGATTGAATTCACTTTTTCGCACAT (SEQ ID NO: 90)
AAATAACTGAATCTGGCCAAGTTATTA (SEQ ID NO: 91)
Tetur01g13610
1126_1276_
No Primers could be designed with these
Tetur19g01440
criteria
114_520_
CTAAAAATCTAATTGCAGTGGTAG (SEQ ID NO: 92)
CGTTTATCTGGCAATGGAG (SEQ ID NO: 93)
Tetur01g13610
1173_1324_
AATGTTTTCTTTGTGCAAGTTTCTTATC (SEQ ID NO: 94)
GCTGGAAGAGTAAAATGTTTAGGT (SEQ ID NO: 95
Tetur01g21600
1186_1376_
ACCTGAGAATCTTTGAGACC (SEQ ID NO: 96)
ATCCTCATCACAACAACCTGAC (SEQ ID NO: 97)
Tetur14g00120
1204_1399_
TAACCTCTTGATCCAGTAAAGCTTCAAT (SEQ ID NO: 98)
GTTTATTAGCTGGTCGTTATGCAC (SEQ ID NO: 99)
Tetur09g01840
1224_1532_
CAAGGAGGTTTCATCAGGATA (SEQ ID NO: 100)
ATGAACATAATTAAAACCTGGTCTTTCG (SEQ ID NO: 101)
Tetur31g00990
1236_1391_
No Primers could be designed with these
Tetur20g01760
criteria
1266_1490_
CTGTCGATTGAACCCTGCAT (SEQ ID NO: 102)
TGTGAACATTGTTCCCATCAACAT (SEQ ID NO: 103)
Tetur16g00420
1326_1516_
No Primers could be designed with these
Teturl9g01440
criteria
1506_1673_
TAAGCATAATAAGTTCTGATAACATCC (SEQ ID NO: 104)
TCTTTGAATGTTGAGTCGGAATG (SEQ ID NO: 105)
Tetur01g13610
1564_1794_
No Primers could be designed with these
Tetur20g01760
criteria
161_321_
CACAAACATAACTTGGCCTAAATCT (SEQ ID NO: 106)
AAGATCATCGTTTAATGGTAATGTTGT (SEQ ID NO: 107)
Tetur02g06230
173_391_
CCACTGTTGGTGTAAGTTGTGAAT (SEQ ID NO: 108)
TTCAATCACTTGTCGATATGAGC (SEQ ID NO: 109)
Tetur01g12090
1761_1957_
TGGATTGTTGATGGTTAGACTC (SEQ ID NO: 110)
GCTGCTGCGGCTGCAACT (SEQ ID NO: 111)
Tetur01g13860
1812_1966_
No Primers could be designed with these
Tetur06g02480
criteria
1821_1979_
TGATTGGCAACAATTACTCGATAT (SEQ ID NO: 112)
TTTAATGTTGCTAAAAGTGGGCCCAAC (SEQ ID NO: 113)
Tetur20g01760
185_411_
TGGGCTACTGATACCGAGTT (SEQ ID NO: 114)
GCCTGACATAGATGGATGGGA (SEQ ID NO: 115)
Tetur05g05120
200_356_
TGAGATGAGTATTTACAGGGG (SEQ ID NO: 116)
TTACGTTCTTCCTCCTATTCTTCA (SEQ ID NO: 117)
Tetur01g12340
2025_2185_
AATTATTGTTGTCACTAATTTCGTGTAC (SEQ ID NO:
CACCATCATCAAAAAGTAAATGATTCC (SEQ ID NO: 119)
Tetur23g02710
118)
210_397_
ATGGTAACCAAGTTTCAGCTAGA (SEQ ID NO: 120)
CAAATCAGGTTAGCTCATACAGACA (SEQ ID NO: 121)
Tetur12g05390
2129_2321_
No Primers could be designed with these
Tetur20g01760
criteria
226_459_
AACATAACCATAAACATCACCACC (SEQ ID NO: 122)
GTGTAACTGTTGGTGATCCAGTTC (SEQ ID NO: 123)
Tetur01g21600
2296_2467_
No Primers could be designed with these
Tetur01g13860
criteria
232_580_
CAACAAATCCATATTCAGTCAAGA (SEQ ID NO: 124)
TTCAGAAGATTCAAGTTACTCATGTC (SEQ ID NO: 125)
Tetur13g05360
2353_2823_
CCTGATTTTTAGTAAGCCCATAAATCC (SEQ ID NO: 126)
CATTTTATAATTATTTGACTGCCTGGGT (SEQ ID NO: 127)
Tetur06g02480
2371_2583_
GATAAATTTGTCCCAATAACATTCGTAA (SEQ ID NO:
AATATGAAGATGATTCATCATACTCTG (SEQ ID NO: 129)
Tetur23g02710
128)
2380_2694_
ATAAGCAGGAGGAGGTTGA (SEQ ID NO: 130)
TTAAACGAAAAAGAAGTCGAACTGG (SEQ ID NO: 131)
Tetur16g00420
409_2604_
CAGTTCAAAGTCACAATTCTCTTTACC (SEQ ID NO: 132)
CAACTACTTGAATCGTTAAGAATTTTCC (SEQ ID NO: 133)
Tetur19g01440
246_442_
No Primers could be designed with these
Tetur01g08220
criteria
2581_2750_
No Primers could be designed with these
Tetur01g13860
criteria
2582_2766_
No Primers could be designed with these
Tetur20g01760
criteria
259_421_
No Primers could be designed with these
Tetur07g08130
criteria
2651_2803_
CAACGATTTCTCTCTCCAACCA (SEQ ID NO: 134)
TGCCAGGCAATTGACTTTGTACGA (SEQ ID NO: 135)
Tetur19g01440
2685_2839_
TGTTTGACTGCCGATGAGA (SEQ ID NO: 136)
TTGTTGAATGAAGAAGACGACCTTT (SEQ ID NO: 137)
Tetur19g0154
2753_2877_
ATGAATGCTTTTGCCAACGG (SEQ ID NO: 138)
GTTAATATTTGTTCTAGCTCTAACTAG (SEQ ID NO: 139)
Tetur06g02480
2809_2985_
AATCAATTTTTTATGCTTAGGATGGAG (SEQ ID NO: 140)
GAGAAATCGTTGAAACGGTCAACTT (SEQ ID NO: 141)
Tetur19g01440
281_523_
TAATGGGCAAAGGAATGGGCGA (SEQ ID NO: 142)
CTTTTCAATCTTTTTGTATATACGACTC (SEQ ID NO: 143)
Tetur16g02700
3048_3213_
TGAAACTAAATTATGATGGTGTCGCTT (SEQ ID NO: 144)
TACATTTTTTCTGGAGCGGTTG (SEQ ID NO: 145)
Tetur06g02480
3059_3244_
CAAGAGAAGCTTTTCTAACAACTA (SEQ ID NO: 146)
GGTACTCATCTCTGCTCACCAA (SEQ ID NO: 147)
Tetur20g01760
305_460_
TTGAACCCAATCCATCTGAATTG (SEQ ID NO: 148)
TGGAGTGGCCTTAATTGGAGT (SEQ ID NO: 149)
Tetur16g00420
3221_3403_
No Primers could be designed with these
Tetur06g02480
criteria
329_689_
AATTTGTCCACATTTTGTCGTAAAG (SEQ ID NO: 150)
CAACAACTTATCACCAATAACAGCA (SEQ ID NO: 151)
Tetur01g13860
3380_3547_
GTTCTAAATTTTTGAAGGCAGCTA (SEQ ID NO: 152)
AAATGATTCTGTTATACCAACAGCAGT (SEQ ID NO: 153)
Tetur20g01760
339_590_
GGTATAGTAATCTCGGGTCCTAA (SEQ ID NO: 154)
CAAACACCAAACAATGACAATCAA (SEQ ID NO: 155)
Tetur06g02480
3466_3739_
TTGTTGTTGTTGGTGAAACAGTTGC (SEQ ID NO: 156)
CATTACCCACATCAACATTTATGG (SEQ ID NO: 157)
Tetur19g01440
347_817_
GAGCATCGGAGGTGTCAA (SEQ ID NO: 158)
GACAAAAAAAGGTTATGTTCGTGG (SEQ ID NO: 159)
Tetur18g02240
365_571_
No Primers could be designed with these
Tetur21g03340
criteria
372_523_
CTGAAGAGTGAAATGCTGATGATCGG (SEQ ID NO: 160)
CATCATCATCACCACAAGTCA (SEQ ID NO: 161)
Tetur19g01540
3732_3946_
CAGAGTCAATTGGTGAACCTT (SEQ ID NO: 162)
CAGGCACAGCAACATCAA (SEQ ID NO: 163)
Teturl9g01540
3986_4372_
No Primers could be designed with these
Tetur19g01540
criteria
417_589_
CCCAACCTTTAACAAAAGAAAGCCTA (SEQ ID NO: 164)
ATGCAACAACAAGCTGCTTCA (SEQ ID NO: 165)
Tetur08g00500
418_692_
TCATAATCATCCTCTTCGCCA (SEQ ID NO: 166)
GCATAAATAATAATCGTGATCCTTTAG (SEQ ID NO: 167)
Tetur19g01440
445_650_
TGTTTCAATGTTGATTCCAATGCACT (SEQ ID NO: 168)
AAAATGTACAAAATGCTAGACCTGA (SEQ ID NO: 169)
Tetur31g01810
4484_4770_
AAAGTCAACAACAAGTTCTACATAAGAT (SEQ ID NO:
TCTTTACAAGGAAACTCGTGATCCTG (SEQ ID NO: 171)
Tetur20901760
170)
463_801_
AACATCTTTAGCCATTTGACTGGCTG (SEQ ID NO: 172)
CCACGATTACAGATGGACCTGA (SEQ ID NO: 173)
Tetur04g03690
4678_4905_
TTGAAGAGGAATTGAATTGCCGCAAA (SEQ ID NO: 174)
ATCATCATCAAGCAGCCAC (SEQ ID NO: 175)
Tetur19g01540
467_666_
TTGCCATTCAGCATATTTGACAGGAT (SEQ ID NO: 176)
CTTCACCAAGAATGGCCAC (SEQ ID NO: 177)
Tetur10g00660
46_199_
TTGTTGTGGTTGTCGTTATAACCT (SEQ ID NO: 178)
GCGATTTAACCACACTTTTCCT (SEQ ID NO: 179)
Tetur14g00860
4755_5024_
TCCTCTTCATCGTCACCGAAACA (SEQ ID NO: 180)
ACCACAACCATCACATTGAAC (SEQ ID NO: 181)
Tetur01g13860
47_255_
AAGGTAAGAGTTGAAAACAAATCCAAG (SEQ ID NO: 182)
AGATGATGCAGAAAGACAAACTCAG (SEQ ID NO: 183)
Tetur26g02710
*494_599_
TACTCCACTAGAGTTATATCATGAGTCT (SEQ ID NO:
AATGGACGATGAACTGGTTAAATT (SEQ ID NO: 185)
Tetur01g08060
184)
50_206_
No Primers could be designed with these
Tetur01g21600
criteria
518_697_
ACCAATAAACATTTCCTTGTGGTG (SEQ ID NO: 186)
CGAGAAATTTTTGGCTCGTGAT (SEQ ID NO: 187)
Tetur01g07940
545_715_
CAAATTTACACTCTCGAGCGCGAGTT (SEQ ID NO: 188)
TTTGCTGGTTGTTGTTCCTAAAGCAT (SEQ ID NO: 189)
Tetur30g02230
5574_6004_
AAATCATTAATGGTAAGCCTTCAC (SEQ ID NO: 190)
AAACGAGAAAAGGCAACTAAATTGG (SEQ ID NO: 191)
Tetur20g01760
566_774_
No Primers could be designed with these
Tetur07g01500
criteria
588_759_
No Primers could be designed with these
Tetur07g05390
criteria
5_168_
ACAAGTGATTGAATTGAATCGACAAA (SEQ ID NO: 192)
CAATGTGAACCAAAACACCTCT (SEQ ID NO: 193)
Tetur01g12090
6075_6322_
No Primers could be designed with these
Tetur20g01760
criteria
643_815_
TATTTTTTTGCCTCGGGCTGAGGT (SEQ ID NO: 194)
ATCGTTATGATGATGAATTGGGTA (SEQ ID NO: 195)
Tetur13g05360
653_806_
No Primers could be designed with these
Tetur19g01540
criteria
694_948_
TTTACCTTTACGGGGAACCAA (SEQ ID NO: 196)
ATGTGGACAAATTTATGAACGAATCGCT (SEQ ID NO: 197)
Tetur01g13860
701_937_
TCATTCGATTGGTAATGAATCGTATCT (SEQ ID NO: 198)
TGGTTTACCTTGTGATCAACTTAATCT (SEQ ID NO: 199)
Tetur21g03340
719_896_
No Primers could be designed with these
Tetur01g12340
criteria
*747_1103_
CGAGTCGAGGTTGACCCACAG (SEQ ID NO: 200)
ATTTTTGTCTCCATTAACTATCGTGTTG (SEQ ID NO: 201)
Tetur18g02240
747_966_
TCTTCTTTGTTGTTTCTTATTGGG (SEQ ID NO: 202)
CAATACAATGAACAAGAAATTGCAGAT (SEQ ID NO: 203)
Tetur30g02230
748_1010_
TAAACTGGAGTGGTTCGCCGTA (SEQ ID NO: 204)
CTCAACAGCAGCAACATGAT (SEQ ID NO: 205)
Tetur16g02700
751_910_
AAATTTTGGTGAATTCATATTCAGACTG (SEQ ID NO:
ATGGAAAAATCTTTGAGGTTAAACATGC (SEQ ID NO: 207)
Tetur31g01810
206)
762_1003_
CACCTTTAACTCCTACTGGAA (SEQ ID NO: 208)
GGTTTAATGGATGACATTTATCAATGG (SEQ ID NO: 209)
Tetur07g08130
764_938_
No Primers could be designed with these
Tetur07g05390
criteria
819_1066_
CTTCCAACACTTGACGAG (SEQ ID NO: 210)
AATAAACATACAAACCGTGAGCC (SEQ ID NO: 211)
Tetur06g02480
868_1056_
No Primers could be designed with these
Tetur14g00860
criteria
943_1154_
TAAAGATCACCGGTTGTCTTGTA (SEQ ID NO: 212)
TTGGTGTTGGTGGCTCGT (SEQ ID NO: 213)
Tetur07g05390
944_1108_
CAAATTCAACATTTTCGGCCATC (SEQ ID NO: 214)
TAAGCCATTAATTAGTGAGAAAGACAT (SEQ ID NO: 215)
Tetur19g01440
94_564_
TACTTGGTGCACTTGTAACAATACGG (SEQ ID NO: 216)
TAACCACAGGCGATATGAG (SEQ ID NO: 217)
Tetur01g08060
[0000]
TABLE 2
primers designed after two runs
SEQ_ID
5_PRIMER
3_PRIMER
0_228_
ATTTTTGTTTTCAAAGATATCGTGGATACAGG (SEQ ID NO:
AGTGAATTTTGGCTCATCTCAG (SEQ ID NO: 219)
Tetur30g02230
218)
1126_1276_
ATTTTGGTAAAATATACTTGGCAGAAAGA (SEQ ID NO: 220)
AAGTATTTGAAAAATATACCCTTGATATG (SEQ ID
Tetur19g01440
NO: 221)
1236_1391_
GCACCAACACTGAAATAACCCCAAA (SEQ ID NO: 222)
AATGATAATCCAATTGACTTCAAATTAGGAC (SEQ ID
Tetur20g01760
NO: 223)
1326_1516_
TTTTGTTCAACATATTTCTTTTGTTTTTACTC (SEQ ID NO:
TATTTTGATTACATGAAGTTACTGATGAGCC (SEQ ID
Tetur19g01440
224)
NO: 225)
1564_1794_
TACATTTTCGTAGATTAGTTCAACATTAAC (SEQ ID NO:
TATTAGAAACGGAAGCTTTCCAG (SEQ ID NO: 227)
Tetur20g01760
226)
1812_1966_
ATTGTTTTTGGTTATGGAGGAATCG (SEQ ID NO: 228)
TATTTACCTTTATTCCATGGAAGATTTTT (SEQ ID NO:
Tetur06g02480
229)
2129_2321_
GCAGAATCAGTTTCACTAGGATTTTTTCCCA (SEQ ID NO:
GAAAATGATAATGACATTAACAACTTCAG (SEQ ID NO:
Tetur20g01760
230)
231)
2296_2467_
ATTGGGATAAAAGTGAATTTGTAATTGATTG (SEQ ID NO:
CATCATCTTCTTCCACCTC (SEQ ID NO: 233)
Tetur01g13860
232)
246_442_
TACTGTTATTATTGTTAGGTTGATTGGCGG (SEQ ID NO:
ACCAATAATAATGGTAGTCTTTATTCAAGT (SEQ ID NO:
Tetur01g08220
234)
235)
2581_2750_
AGAAACATTTTCATTCTAATGAAAGGTTC (SEQ ID NO: 236)
ATACTGAAGACATCGTCAAGAAGG (SEQ ID NO: 237)
Tetur01g13860
2582_2766_
TTTAAGTAAATCTTGAACACAACTTCTTAAAC (SEQ ID NO:
TGCCAAGAATATAACCGCTG (SEQ ID NO: 239)
Tetur20g01760
238)
259_421_
GAGTATATGTTTTATATTCCATCAGTTTT (SEQ ID NO: 240)
AGCCTCATGAAAAAGTGATCCAA (SEQ ID NO: 241)
Tetur07g08130
3221_3403_
TATCATCAGGTAAATGTGAGGTAGT (SEQ ID NO: 242)
TTTAGTTTCATATTCACGACGTATTTATC (SEQ ID NO:
Tetur06g02480
243)
365_571_
No Primers could be designed with these
Tetur21g03340
criteria
3986_4372_
No Primers could be designed with these
Tetur19g01540
criteria
50_206_
GATGTTTCTTCATAAACTTGAATGGTTGCT (SEQ ID NO:
AAATGAAAAATTATACGGATATGTCCAAGGAG (SEQ ID
Tetur01g21600
244)
NO: 245)
566_774_
No Primers could be designed with these
Tetur07g01500
criteria
588_759_
No Primers could be designed with these
Tetur07g05390
criteria
6075_6322_
CAATAATCTTTTTACAGATAACGTCATTT (SEQ ID NO: 246)
CTGAAATTTGGTGCTCAAATCGT (SEQ ID NO: 247)
Tetur20g01760
653_806_
TTACAGCTAATATTGTTCTCTTTGTATTG (SEQ ID NO: 248)
GTCACCATCATCTAGTTACGCCCTACCA (SEQ ID NO:
Tetur19g01540
249)
719_896_
TAAACAGGAGAAATGGTGACATTTAT (SEQ ID NO: 250)
AGAAAAATTTATTTATCGTCTCGAATTAAAC (SEQ ID
Tetur01g12340
NO: 251)
764_938_
CCACCAACACCAACGGAT (SEQ ID NO: 252)
TGAAGCTTTTTTCAAACTTTTCTATTACT (SEQ ID NO:
Tetur07g05390
253)
868_1056_
TTCACTTTTAGGTTGCTGTGG (SEQ ID NO: 254)
TTCAATCACATCATTACAATGTTAAAACACG (SEQ ID
Tetur14g00860
NO: 255)
[0000]
TABLE 3
primers designed after 3 runs
SEQ_ID
5_PRIMER
3_PRIMER
365_571_
TATTAACAATATTATTAACATTGGTAGGA (SEQ ID NO:
GCAACATTGGAATACCAT (SEQ ID NO: 257)
Tetur21g03340
256)
3986_4372_
CTGCCGCTGCTGCAGCCG (SEQ ID NO: 258)
TGACTTGAGTGATTTAGCAAGTGA (SEQ ID NO: 259)
Tetur19g01540
566_774_
GTTGGTCACTTTGAAAATACGA (SEQ ID NO: 260)
TAATGCTAATATATTTTTTGTGATACT (SEQ ID NO: 261)
Tetur07g01500
588_759_
GAAAAAAGCTTCAGCAAAGT (SEQ ID NO: 262)
TCTAATATTTGTGTTTATATATCATCAT (SEQ ID NO: 263)
Tetur07g05390
Example 3
Expression of RNAi in Plants
[0025] Similar to the RNAi distal-less construct, RNAi constructs of the other essential genes are placed under control of the CaMV 35 S promoter, in pB-Agrikola. The plasmid map of pB Agrikola (carrying the RNAi construct of Tetur17g02200-SEQ ID NO:86) is given in FIG. 4 ; the sequence of the plasmid is given in SEQ ID NO:267. In a similar way, constructs were made for the RNAi of SEQ ID NOS:2, 18, 22 and 75. The resulting constructs were agro-infiltrated into Arabidopis . RNAi expression is checked by Northern blot. RNAi positive lines are further cultivated to be used in a feeding test.
Example 4
Feeding Tests with T. urticae
[0026] Arabidopsis plants expressing dsRNA from the selected genes are used in spider mite food tests, and the effect on mite development is measured, as described in Example 1. A reduction in living mites, as well in eggs, on the plants is obtained.
REFERENCES
[0000]
Baum J. A., T. Bogaert, W. Clinton, G. R. Heck, P. Feldmann, O. Ilagan, S. Johnson, G. Plaetinck, T. Munyikwa, M. Pleau, T. Vaughn and J. Roberts (2007). Control of coleopteran insect pests through RNA interference. Nature Biotech. 25:1322-1326.
Cobos I., V. Broccoli, and J. L. Rubenstein (2005). The vertebrate ortholog of Aristaless is regulated by Dlx genes in the developing forebrain. J. Comp. Neurol. 483:292-303.
Fonseca N. A., C. P. Vieira, and J. Vieira (2009). Gene classification based on amino acid motifs and residues: the DLX (distal-less) test case. PLoS One, 4:e5748.
Gordon K. H. J and P. M. Waterhouse (2007). RNAi for insect-proof plants. Nature Biotech. 25:1231-1232.
Mao Y. B., W. J. Cai, J. W. Wang, G. J. Hong, X. Y. Tao, L. J. Wang, Y. P. Huang, and X. Y. Chen (2007). Silencing a cotton bollworm P450 monooxygenase gene by plant-mediated RNAi impairs larval tolerance of gossypol. Nat. Biotechnol. 25:1307-1313.
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The present invention relates to a method of controlling spider mites on plants. More specifically, the invention relates to plants expressing RNAi of one or more essential genes of the spider mite, and the use of those plants to control the spider mite proliferation into pest proportions. In a preferred embodiment, the spider mite is Tetranychus urticae.
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FIELD OF THE INVENTION
[0001] The invention relates to a method and an apparatus for processing printing ink containing inhibitors and oligomers in a printing unit of a rotary printing machine.
BACKGROUND OF THE INVENTION
[0002] A printing ink which contains inhibitors and oligomers and is preferably solvent-free and has constituents that can crosslink. While the inhibitors prevent crosslinking of the ink constituents, the inhibitors break down as the result of splitting of the ink into a thin ink film (the principle of ink splitting) and under the action of oxygen in the air.
[0003] A disadvantage in the processing of printing ink of this type is that, for specific applications, in particular subsequent processing, the printing ink is not sufficiently dried on the printing material.
OBJECTS AND SUMMARY OF THE INVENTION
[0004] It is an object of the present invention to provide a method and apparatus for processing printing ink containing inhibitors and oligomers of the foregoing type in which the ink has shortened drying times and can be used with improved printing quality.
[0005] A first advantage of the invention is that the printing ink when applied on the printing material can be dried much faster. As a result, further processing of the printing material can be carried out more efficiently in a rotary printing machine.
[0006] A further advantage is that processing of the printing ink can be implemented in a number of the most important printing processes, such as wet offset (using damping solution), dry offset (free of damping solution), letterpress printing, and flexographic printing.
[0007] Specifically in offset printing units having damping units (wet offset) or offset printing units for printing free of damping solution (dry offset), it is advantageous to accelerate the drying process for the printing ink by adding a catalyst which accelerates the breakdown of the inhibitors to the damping solution (wet offset) or to the printing ink (dry offset). In this case, it is not necessarily required to introduce the catalyst into all of the offset printing units. Depending on the desired state of drying of the printing ink on the printing material, the catalyst may be added only in selected of the offset printing units. Preferred offset printing units for the addition of catalysts are—as considered in the conveying direction of the printing material—printing units which are arranged upstream of a sheet turning device and/or a varnishing unit and/or upstream of a sheet deliverer.
[0008] Alternatively, in varnishing units operating with a letterpress printing process or a planographic printing process, it is advantageous that the drying of the varnish be accelerated by means of the addition of a catalyst to the varnish that accelerates the breakdown of the inhibitors. Here too, the use of a catalyst is not absolutely necessary in all varnishing units (in the event of a multiple arrangement of varnishing units). Depending on the desired state of drying of the varnish on the printing material, the catalyst can be introduced in selected varnishing units.
[0009] Thus, it also is advantageous that the method and apparatus are not restricted to the processing of a printing ink containing inhibitors and oligomers; the process of a varnish containing inhibitors and oligomers can likewise be implemented. The term printing ink, as used herein, therefore also includes such a varnish.
[0010] Other objects and advantages of the invention will become apparent upon reading the following detailed description and upon reference to the drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] [0011]FIG. 1 is a partially diagrammatic side elevational view of a rotary printing machine in accordance with the invention having at least one printing unit and at least one varnishing unit; and
[0012] [0012]FIG. 2 shows an alternative embodiment of a rotary printing machine having a turner device arranged between two printing units;
[0013] While the invention is susceptible of various modifications and alternative constructions, certain illustrative embodiments thereof has been shown in the drawings and will be described below in detail. It should be understood, however, that there is no intention to limit the invention to the specific forms disclosed, but on the contrary, the intention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] Referring now more particularly to FIG. 1 of the drawing, there is a shown a rotary printing machine which includes a plurality of printing units for multicolor printing, for example offset printing units, in an in-line design (only one of which is illustrated). A varnishing unit II is arranged downstream of the last printing unit I in the conveying direction 10 of the printing material. The printing material is transported in the conveying direction 10 by means of cylinders 2 of the printing and varnishing units and intermediate transfer cylinders 4 .
[0015] The printing unit I includes a plate cylinder 5 which, for example, carries a replaceable printing forme, and is in contact with a cylinder 1 . Alternatively, an image can be set directly on the plate cylinder 5 , for example by the thermal transfer process, and the printing image produced on the plate cylinder 5 can be erased.
[0016] In the illustrated embodiment, the cylinder 1 is a blanket cylinder in contact with the cylinder 2 , which is a sheet carrying cylinder. Alternatively, the cylinder 2 can be designed as an impression cylinder or blanket cylinder. In order to transfer printing ink supplied by the cylinder 1 and containing inhibitors and oligomers to the printing material, a press nip 3 (or a varnishing nip 3 in the case of varnishing units) is formed in the contact area of the cylinders 1 , 2 . The plate cylinder 5 is at least coupled to an inking unit, upstream of which a damping unit may be arranged if required.
[0017] In carrying out the invention, an applicator device 7 is arranged downstream, preferably immediately downstream of the press nip 3 formed by the cylinders 1 , 2 . If a sheet directing or carrying device, for example a blown air device, is arranged downstream of the press nip 3 , then the applicator device 7 is arranged downstream of the sheet directing and carrying devices in the conveying direction 10 . The applicator device 7 preferably includes an applicator roll 12 which can be set on and off in the direction of the cylinder 2 , and is connected to a supply device, for example a supply container, arranged upstream. The applicator roll 12 preferably has a resilient outer covering.
[0018] In further carrying out the invention, a thermally active dryer device 8 in this case is arranged downstream of the applicator device 7 in the conveying direction 10 . The illustrated dryer device 8 , as shown in FIGS. 1 and 2, is arranged adjacent to and at a defined distance from the cylinder 2 . Alternatively, a separate drier section also can be arranged downstream of the cylinder 2 , for example in association with a plurality of transfer cylinders when processing sheet material, or an endlessly circulating chain system, in each case having at least one dryer device or dryer systems when processing web material.
[0019] In the varnishing unit II (FIG. 1), a cylinder 1 , for example, a forme cylinder with a replaceable varnishing forme, is coupled to a metering system 6 having at least one applicator roll, for example formed by a chamber-type doctor 13 and an engraved applicator roll 14 . Alternatively, known two-roll units having a common nip with varnish supplied into the nip, or a roll system on the dip/scoop roll principle with a roll dipping into a container (with varnish/ink), together with at least one applicator roll, can be used as metering systems.
[0020] The cylinder 1 is in contact with the cylinder 2 in a varnishing nip 3 in order to transfer the varnish supplied by the cylinder 1 and containing inhibitors and oligomers to the printing material. In the present example, the cylinder 2 is constructed as a sheet carrying cylinder in a way analogous to the cylinder 2 in the printing unit I.
[0021] In a way analogous to the printing unit I, in the conveying direction 10 , an applicator device 7 is arranged downstream, preferably immediately downstream, of the cylinder 1 which is constructed as a forme cylinder. The applicator device 7 is arranged in the varnishing unit II as a spray device, for example, which extends over the maximum printing material width.
[0022] Preferably, a thermally active dryer device 8 again is arranged downstream of the applicator device 7 in the conveying direction 10 . In this case, the dryer device 8 —as shown in FIGS. 1 and 2—is arranged adjacent to and at a defined distance from the cylinder 2 . Alternatively, a separate drier section can also be arranged downstream of the cylinder 2 , for example in association with a plurality of transfer cylinders when processing sheet material or an endlessly circulating chain system, in each case having at least one dryer device or dryer systems when processing web material.
[0023] Referring to FIG. 2, two identical printing units I are shown. Arranged between the two cylinders 2 is a turning device 9 , which functions as a sheet carrying cylinder as well as turning the sheet printing material within the printing machine using the principle of trailing-edge turning. A dryer device 8 preferably is arranged upstream of the turner device 9 . This arrangement is advantageous in that the printing material is noticeably drier before being transferred to the turner device 9 , and the printed side is set off noticeably less during the turning process or on the downstream cylinder 2 .
[0024] The method sequences according to the invention may be carried out consistent with two basic principles.
[0025] The method sequences according to the 1st principle are as follows:
[0026] In a press/varnishing nip 3 formed by the two cylinders 1 , 2 , the printing ink or the varnish is applied by at least one inked cylinder 1 , 2 to a printing material, preferably in accordance with the printing subject and, after passing through the press/vanishing nip 3 , the printing ink adhering to the printing material or the varnish adhering to the printing material has applied to it a catalyst mixture that accelerates the breakdown of the inhibitors. As a result, the crosslinking process of the printing ink or of the varnish is accelerated significantly so that the drying times for the ink or of the varnish are shortened.
[0027] In one preferred embodiment, the printing ink or the varnish is applied to one side of the printing material by a cylinder 1 constructed as a blanket cylinder or forme cylinder, and the catalyst mixture is then applied to the printing ink or the varnish adhering to the printing material. In a further embodiment, the printing ink or the varnish is applied to both sides of the printing material by two cylinders 1 , 2 constructed as blanket cylinders or forme cylinders (rubber against rubber principle), and then the catalyst mixture is applied to both sides of the printing ink or the varnish adhering to both sides of the printing material.
[0028] In a further embodiment, at least one, preferably each printed side of the printing material is dried thermally on each printed side following the application of the catalyst mixture.
[0029] When a turner device is arranged within the rotary printing machine, the catalyst mixture is applied to the printing material immediately in the printing unit before the turning.
[0030] The method sequences according to the 2nd principle are as follows:
[0031] In a press/varnishing nip 3 formed by two cylinders 1 , 2 , the printing ink or the varnish is applied to a printing material by at least one inked cylinder 1 , 2 , preferably in accordance with the printing subject. In this case, the inked cylinder 1 , 2 also carries a catalyst mixture which accelerates the breakdown of the inhibitors. The catalyst mixture has a defined reaction time so that the crosslinking process of the ink or of the varnish for accelerating the drying takes place after the press/varnishing nip 3 has been passed.
[0032] At least one inking unit, preferably having at least one roll train, is preferably assigned to the plate cylinder 5 of a printing unit. In this case, the catalyst mixture is applied to the plate cylinder 5 by means of an inking unit.
[0033] For this purpose, for example, the catalyst mixture is added into an ink fountain accommodating the specific printing ink and is supplied to the plate cylinder 3 together with the printing ink via the roll train. Alternatively, the catalyst mixture is supplied to a roll in the inking unit which carries the specific printing ink and is supplied to the plate cylinder 3 together with the printing ink.
[0034] In a further preferred embodiment, a damping unit is arranged upstream of the inking unit and the plate cylinder 5 in the direction of rotation of the latter. In this embodiment, the catalyst mixture is added to the damping solution, so that the damping solution and the catalyst mixture is transferred to a plate cylinder by means of an applicator roll. Depending on the construction of the damping unit, the damping solution and the catalyst mixture can also be completely or partly transferred into the inking unit and transferred from the inking unit to the plate cylinder 5 , together with the printing ink, by means of at least one applicator roll.
[0035] In particular in the case of a varnishing unit II having cylinders 1 , 2 and a press/varnishing nip 3 and also a metering system having at least one applicator roll, the catalyst mixture is transferred to at least one of the cylinders 1 , 2 , preferably the forme cylinder, via this applicator roll. In this case, the crosslinking of the printing ink or of the varnish also takes place downstream of the press/varnishing nip 3 .
[0036] In this case, at least one, preferably each printed or varnished side of the printing material is preferably dried thermally after the inking or varnishing and the preferred, simultaneous application of the catalyst mixture. If a turner device is arranged in the rotary printing machine, then the catalyst mixture is preferably applied immediately to the printing material in the printing unit I or varnishing unit II before the turning.
[0037] It will be understood that the method sequences according to principles 1 and 2 described above are not restricted to the presence of printing ink or varnish in the printing unit I or varnishing unit II supplying the catalyst mixture. Instead, the catalyst mixture can also be applied separately to at least one of the cylinders 1 , 2 in a printing or varnishing unit I, II that is not involved in the printing or varnishing. Likewise, the catalyst mixture can be processed separately or mixed with the printing ink or the varnish, alternatively with the damping solution.
[0038] In summary, the machine configuration is constructed substantially as follows:
[0039] In a first embodiment, in the conveying direction 10 of a printing material, at least one applicator device 7 having an applicator roll 12 for applying a catalyst mixture to the printed side of the printing material is arranged downstream of a press/varnishing nip 3 formed by two cylinders 1 , 2 . In a second embodiment, in the conveying direction 10 of a printing material, at least one applicator device 7 having a spray device 15 pointing parallel to the cylinder axes (cylinders 1 , 2 ) for applying a catalyst mixture to the printed side of the printing material is arranged downstream of a press/varnishing nip 3 formed by two cylinders 1 , 2 .
[0040] In a further embodiment, in particular for web printing materials, downstream of the press/varnishing nip 3 formed by the cylinders 1 , 2 , in each case an applicator device 7 having at least one applicator roll 12 for applying the catalyst mixture to the printing material is assigned to both sides of the printing material.
[0041] In an equivalent embodiment, at least one applicator device 7 in each case having a spray device for applying the catalyst mixture to both sides of the printing material is in each case arranged downstream of the press/varnishing nip 3 .
[0042] Depending on the requirement on the level of drying of the printing ink or of the varnish, at least one dryer device 8 is arranged downstream of at least one, preferably all, of the applicator devices 7 .
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A method and apparatus for processing a printing ink containing inhibitors and oligomers in a printing unit of a rotary printing machine in which the drying times of the printing ink on the printing material is shortened and the printing quality improved. In the illustrated embodiments, the printing unit includes two cylinders that form a press nip in which the printing ink is applied to passing printing material, and a catalyst mixture is applied to the printing material either by one of the cylinders or through an applicator device downstream of said press nip. A heating device is located in the conveying direction immediately downstream of the press nip or the applicator device.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is related to and claims priority to Norwegian Patent Application Serial No. 20151356, filed Oct. 8, 2015, entitled IMPROVED DOLLY SYSTEM, the entirety of which is incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
n/a
TECHNICAL FIELD
Camera dolly systems are used in the television (TV) and motion picture industries to support and maneuver a camera. Typically, a camera dolly comprises a platform on wheels and has an arm to raise and lower the camera. The camera dolly is generally moved by dolly operators either by a manual hands-on steering or by means of a motor remotely controlled by operators in a remote control room.
BACKGROUND
In the production of motion pictures, a motion picture camera must often be moved from one position to another. The camera movements may require a change in camera position, camera angle or camera elevation. The camera movement must be performed smoothly, as even small amounts of vibration of the camera can result in unsatisfactory filming results, due to shaky or erratic recorded images. Similar requirements must often be met in the case of TV studio productions, e.g. predefined camera movements that are to be performed along the studio floor.
Camera dollies and pedestals have long been used to support and move motion picture cameras. Typically, a camera dolly has four wheels or pairs of wheels on a platform or chassis having a square shaped wheel base. The wheels may be attached to the chassis via articulated legs, or the wheels may be directly pivotally attached to the chassis. The camera dolly must support and enable maneuvering of the camera with a minimum of vibration or shock, to avoid degrading the filmed image quality. Consequently, a camera dolly must be designed, manufactured and maintained with precision, and the dolly may be placed on rails or tracks on the studio floor to provide an even and smooth rolling surface.
Regular camera dollies roll over rail tracks that have joint cuts between rail sections perpendicular to the direction of elongation of the rail track. A drawback with this is that, at some point each wheel will roll over these joint cuts. Therefore, there are points where the wheel is only supported by cuts between two rail sections. This joint has the potential to create a bump or jerk as the wheel roll over it. As mentioned above, the dolly of a TV or motion picture camera must be very smooth otherwise the bump or jerk will be seen on the resulting recording/film.
A currently available solution for mitigating this drawback is micro-accurate engineering in the process of manufacturing the ends of rail sections, often using heavy and expensive metal work machinery. Typically, prior art rail sections have a solid rod that protrudes from the end of one section and a round hollow receptor in the end of the other section. These are called the male and female ends of the sections and they slot together and kept tight with a locking system. If there is any gap or if the two sections are not absolutely straight, the joints will cause slight jerks when the dolly platform wheels roll over them. To minimize this bump or jerk, much time and effort is used during the setup of the dolly system so as to ensure the camera does not feel any bump.
However, such prior art solutions further require rail tracks of relatively large dimensions, and when being placed on top of a studio floor, creates an obstacle protruding up to 20 cm from the floor surface. On the other hand, an immersion of such a rail track to avoid it being an obstacle would require a deep trench in the floor, which would represent a permanent damage in the floor structure, and limit the possibility mobility, for reorganizing the studio and for using the studio for other purposes than TV production.
Another problem with camera dollies on rail tracks is the well-known rail wheel squeal which is a noise that is generated when a dolly moves more or less rapidly along rail track curves. Needless to say, studio noise is particularly important to avoid in TV studios because of the nature of the indoor environment of reflections and small distances from sound source to sound recorders.
Therefore there is a need for arrangements related to a dolly system that are capable of resolving or at least mitigating at least some of the abovementioned drawbacks.
The prior art includes U.S. Pat. No. 6,557,775 where a dolly system is described, which has drawbacks as discussed above.
SUMMARY
In view of the above, an object of the present disclosure is to overcome or at least mitigate at least some of the drawbacks related to dolly systems.
This is achieved in one aspect by a dolly system a dolly system that comprises a dolly platform, a rail assembly and at least one wheel assembly. The rail assembly comprises at least one elongated rail section configured to be joined together to form a rail track. An elongated continuous resilient element, e.g. made by a rubber, is configured to be attached to the at least one rail section along the rail track. The at least one wheel assembly is configured to be attached to the dolly platform and configured to roll along the rail track on top of the elongated continuous resilient element. The wheel assembly comprises a center wheel configured to support the dolly platform in a vertical direction, z, a first lateral support wheel and a second lateral support wheel. The lateral support wheels are configured to support the dolly platform in a horizontal direction, x. The first lateral support wheel and the second lateral support wheel are arranged concentrically and on either side with respect to the center wheel. The first lateral support wheel and the second lateral support wheel have a respective radial extension, r 1 , r 2 , that are larger than a radial extension, r 0 , of the center wheel and the first lateral support wheel and the second lateral support wheel are configured to rotate independent of each other and independent of the center wheel.
In other words, drawbacks related to unwanted noise and jerks of prior art dolly systems are overcome by the dolly system of the present disclosure. The independently rotating lateral support wheels in combination with a center wheel interact with the continuous resilient element when rolling along the rail track, without encountering any gaps or bumps and without producing squeal noise due to so-called wheel-climbing that may occur in curves along the rail track.
Embodiments include those where a cross section of the continuous resilient element, perpendicular to a direction of elongation of the continuous resilient element, matches a profile of a radial cross section of the wheel assembly.
Embodiments include those where the elongated continuous resilient element has a length that corresponds to a length of the rail track.
In some embodiments, a profile of a cross section of the continuous resilient element, perpendicular to a direction of elongation of the continuous resilient element is such that, when attached to the at least one rail section, an elongated cavity is formed between the at least one rail section and the resilient element.
In a second aspect there is provided a rail assembly for a dolly system. The rail assembly comprises at least one elongated rail section configured to be joined together to form a rail track and an elongated continuous resilient element configured to be attached to the at least one rail section along the rail track.
In a third aspect there is provided a wheel assembly for a dolly system. The wheel assembly is configured to be attached to a dolly platform and configured to roll along a rail track on top of an elongated continuous resilient element. The wheel assembly comprises a center wheel configured to support the dolly platform in a vertical direction, z, a first lateral support wheel and a second lateral support wheel. The lateral support wheels are configured to support the dolly platform in a horizontal direction, x. The first lateral support wheel and the second lateral support wheel are arranged concentrically and on either side with respect to the center wheel. The first lateral support wheel and the second lateral support wheel have a respective radial extension, r1, r2, that are larger than a radial extension, r0, of the center wheel and the first lateral support wheel and the second lateral support wheel are configured to rotate independent of each other and independent of the center wheel.
These other aspects have various embodiments, effects and advantages that correspond to those discussed above in connection with the first aspect.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the present invention, and the attendant advantages and features thereof, will be more readily understood by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein:
FIGS. 1 a and 1 b are schematically illustrated perspective views of a dolly system;
FIG. 2 is a view from above schematically illustrated rail track;
FIG. 3 schematically illustrates, in cross-section, a continuous resilient element;
FIG. 4 schematically illustrates, in cross-section, a wheel assembly and a rail assembly; and
FIG. 5 schematically illustrates, in cross-section, a wheel assembly with an attached motor.
DETAILED DESCRIPTION
With reference to FIGS. 1 a and 1 b , the present disclosure relates to a dolly system 100 . FIGS. 1 a and 1 b are perspective views of the dolly system 100 . The dolly system 100 comprises a dolly platform 110 , a rail assembly 120 and a plurality of wheel assemblies 130 .
In the exemplifying embodiment of FIGS. 1 a and 1 b , the dolly platform 110 is trapezoid shaped with one wheel assembly 130 mounted on the short side 161 of the trapezoid shaped dolly platform 110 and two pairs of three parted wheel assemblies 130 mounted on the long side 162 of the trapezoid shaped dolly platform 110 , respectively placed near each edge of the dolly platform 110 .
The rail assembly 120 comprises a plurality of elongated rail sections 121 , for example in the form of milled aluminum profiles. The elongated rail sections 121 are configured to be joined together to form a rail track 143 . Needless to say, in FIGS. 1 a and 1 b , the elongated rail sections 121 are few in numbers and the rail track 143 is therefore relatively short. In fact, embodiments of a rail assembly 120 include those having only a single rail section 121 . In such embodiments, the rail track 143 is realized by such a single rail section 121 . However, in the following, the number of rail sections 121 is plural.
FIG. 2 illustrates, schematically, how a larger number of rail sections have been joined to form rail tracks 143 having a length L and on top of which rail tracks 143 , the dolly platform 110 is located. Moreover, in FIG. 2 a curve 150 in the rail tracks 143 is also illustrated.
The rail assembly 120 further comprises an elongated continuous resilient element 122 . The continuous resilient element 122 is configured to be attached to the rail sections 121 along the rail track 143 and it may have a length that corresponds to the length, L, of the rail track 143 . The elongated continuous resilient element 122 may be made of a rubber, i.e. any appropriate synthetic or natural elastomeric polymer, which has been extruded in a suitable extrusion apparatus or manufactured in any other appropriate manner.
As illustrated in FIG. 2 , long seamless tracks 143 are provided for camera dollies, the rail tracks 143 having no bumps. Moreover, the rail assembly 120 is very compact and thereby enables a less visible structure that does not form an obstacle on a floor on which it is arranged and, as discussed above, a camera mounted on the dolly platform creates no noise that may be disturbing when moving along the rail tracks 143 .
As FIG. 3 and FIG. 4 illustrate, a profile 123 of a cross section of the continuous resilient element 122 , perpendicular to a direction of elongation of the continuous resilient element 122 is such that, when attached to the rail sections 121 , an elongated cavity 124 , or “slit”, is formed between the rail sections 121 and the resilient element 122 . Such a cavity 124 may provide a certain grade of flexibility when exposed to the weight of a camera and dolly platform 110 via the wheel assemblies 130 .
Turning now to FIG. 4 , a wheel assembly 130 will be described in some more detail. The wheel assembly 130 is configured to be attached to the dolly platform 110 and configured to roll along the rail track 143 on top of the elongated continuous resilient element 122 . As FIG. 4 illustrates, the wheel assembly 130 comprises a center wheel 131 that is configured to support the dolly platform 110 in a vertical direction, z. The wheel assembly further comprises a first lateral support wheel 132 and a second lateral support wheel 133 . These first and second lateral support wheels 132 , 133 are configured to support the dolly platform 110 in a horizontal direction, x. The first lateral support wheel 132 and the second lateral support wheel 133 are arranged concentrically and on either side with respect to the center wheel 131 . Moreover, the first lateral support wheel 132 and the second lateral support wheel 133 have a respective radial extension, r1, r2, that are larger than a radial extension, r0, of the center wheel 131 and the first lateral support wheel 132 and the second lateral support wheel 133 are configured to rotate independent of each other and independent of the center wheel 131 .
In other words, the wheel assembly 130 may be seen as a three-parted construction having a weight bearing center wheel and two lateral wheels that perform a “steering” function. The center wheel 131 , attached to or integrated with an axle 135 , is formed as a bar with the gravity force of a camera and dolly platform 110 acting vertically towards the top of the elongated resilient, e.g. rubber, element 122 . The two lateral support wheels 132 , 133 are tightly but independently rotationally connected on each side of the center wheel 131 , preferably by means of a respective ball bearing 136 , 137 .
As exemplified in FIG. 4 , a profile 140 of a cross section of the continuous resilient element 122 , perpendicular to a direction of elongation of the continuous resilient element 122 , may match a profile 141 of a radial cross section of the wheel assembly 130 . That is, in such an example, the combined cross section profile 141 of the center wheel 131 and the two lateral support wheels 132 , 133 is such that it corresponds to the cross sectional profile 140 of the continuous resilient element 122 . The two lateral support wheels 132 , 133 provide support in the x-direction via surface sides of the continuous resilient element 122 .
As exemplified in FIG. 2 , when the dolly platform 110 (comprising wheel assembly 130 ) moves along the rail track 143 into a rail curve 150 , an outer side 171 of the rail track 143 and a corresponding outer surface of the continuous resilient element 122 will be longer than an inner side 172 of the rail track 143 and a corresponding inner surface of the continuous resilient element 122 , and since the two lateral support wheels 132 , 133 are able to rotate independently, a lateral support wheel 132 , 133 that is in contact with the outer side 171 will travel farther than a lateral support wheel 132 , 133 that is in contact with the inner side 172 , a distance corresponding to a difference in lengths of inner and outer surface sides of the continuous resilient element 122 . Consequently, so-called “wheel climbing” on the rail track 143 in the curve 150 creating noise in the form of rail wheel squeal will then be avoided, and no such noise will be captured by a microphone during recording using the dolly system 100 .
FIG. 5 illustrates an embodiment of a wheel assembly 530 that comprises a motor 501 . The motor 501 is connected and adjusted to apply a moment of force on an axle 535 of a center wheel 531 for enabling movement of a camera mounted on a dolly platform, such as the dolly platform 110 illustrated in FIGS. 1 and 2 , along a rail track such as the rail track 143 illustrated in FIGS. 1 and 2 .
It must be emphasized that the terminology “comprise/comprises” as used in this specification is chosen to specify the presence of stated features, numbers, steps or components, but does not preclude the presence or addition of one or more other functions, numbers, steps, components or groups thereof. It should also be noted that the word “a” or “an” preceding an element does not exclude the presence of a plurality thereof.
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A dolly system is disclosed, which overcomes drawbacks related to unwanted noise and jerks of prior art dolly systems. The dolly system comprises wheel assemblies ( 130 ) that have independently rotating lateral support wheels ( 132, 133 ) in combination with a center wheel ( 131 ) that interact with a continuous resilient element ( 122 ) when rolling along a rail track, without encountering any gaps or bumps and without producing squeal noise due to so-called wheel-climbing that may occur in curves along the rail track.
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RELATED APPLICATIONS
This application claims priority from U.S. Provisional Patent Application No. 60/476,446, filed Jun. 6, 2003.
TECHNICAL FIELD
The present invention relates to a microporous polyolefin film, a battery separator including the film, and a lithium battery made using the separator.
BACKGROUND OF THE INVENTION
The lithium-ion battery market has undergone dynamic growth ever since Sony introduced the first commercial cell in 1991. With their energy densities exceeding 130 Wh/kg and cycle lifetimes of more than 1,000 cycles, lithium-ion battery systems have become increasingly popular in applications such as portable computers, camcorders, and cellular phones. J. Power Sources 70 (1998) pp. 48-54. Lithium-ion batteries are the preferred power source for most portable electronic applications because of their higher energy density, longer cycle life, and higher operational voltage as compared with nickel-cadmium and nickel metal hydride batteries. Lithium-ion batteries also provide advantages when compared with lithium batteries in that they generally use a carbon-based anode as opposed to highly reactive metallic lithium. The carbon anode functions via the intercalation of lithium ions between graphene sheets. The cathode materials most commonly used in lithium-ion batteries are lithium cobalt oxide and lithium manganese oxide.
Lithium-ion batteries are produced in spiral wound and prismatic configurations in which a separator is sandwiched between anode and cathode ribbons. The pores of the separator are then filled with an ionically conductive electrolyte formed by dissolving a salt, for example LiPF 6 , in an organic solvent, for example, 50:50 ethylene carbonate:dimethyl carbonate. The principal functions of the separator are to prevent electronic conduction (i.e., shorts) between the anode and cathode while permitting ionic conduction via the electrolyte. As such, a preferred separator is insoluble in the organic solvent, chemically stable against the electrolyte and electrode active materials, and includes suitably sized pores in its matrix.
The introduction of the rechargeable lithium-ion battery precipitated a need for separators that did more than serve as inert, porous films. Separators were not only required to provide good mechanical and electrical properties, but they also had to incorporate a thermal shutdown mechanism for improved cell safety under conditions of high temperature, overcharge, or physical penetration of the battery can. Specifically, preferred separators have a so-called “fuse effect” in which upon reaching a specified temperature the separator becomes molten and the separator pores collapse to minimize ionic conduction between the electrodes should the battery overheat or short circuit. The “fuse effect” prevents potential ignition of the electrolyte and explosion of the battery.
Most commercially available lithium-ion batteries include microporous polyolefin separators. Such separators are typically made from polyethylene (PE), polypropylene, or some combination thereof because polyolefins provide excellent mechanical properties and chemical stability at a reasonable cost. Because many polypropylene separators have a shutdown temperature that is too high (>160° C.) for use in lithium-ion applications, PE separators are preferred. However, certain polyolefin separators often do not fully shutdown, because of “hole formation” that results from shrinkage and poor mechanical integrity under pressure and high temperature. In contrast, ultrahigh molecular weight PE (UHMWPE)-based separators have good high temperature integrity and sufficient polymer flow to cause pore collapse, thereby preventing current flow between the electrodes and through the separator. Consequently, UHMWPE-based separators are transformed into a nonporous film upon shutdown. UHMWPE-based separators often include linear low density PE (LLDPE), high density PE (HDPE), low density PE (LDPE), or another form of PE to manipulate the shutdown temperature or shutdown rate without compromising mechanical integrity. In the case of a PE microporous separator, the fuse temperature, i.e., the temperature at which the thermal shutdown is effected, is between about 120° C. and about 150° C. Thus separators containing UHMWPE offer desirable safety features for use in lithium-ion batteries.
Significant research has been done to perfect the shutdown mechanism of the battery separator. However, little research has been done on methods to scavenge adventitious moisture or acid from lithium or lithium-ion batteries. The presence of water molecules and certain acids (e.g., hydrofluoric acid (HF)) in lithium or lithium-ion batteries is detrimental to battery performance because the water or acid can react with the dissolved salt in the electrolyte, the anode, the cathode, or the battery can. These side reactions inhibit battery performance.
It is therefore desirable to provide for use in lithium or lithium-ion batteries a microporous polyolefin separator exhibiting excellent mechanical strength and electrical resistance properties, a thermal shutdown mechanism, and water- or acid-scavenging capability.
SUMMARY OF THE INVENTION
An object of the present invention is to provide for use in a lithium or lithium-ion battery a separator that provides a thermal shutdown mechanism, excellent mechanical integrity and electrical resistance properties, and water-scavenging or acid-scavenging capability such that water or acid molecules in the battery react with functional groups distributed throughout the separator.
The present invention is a battery separator that provides a thermal shutdown mechanism, excellent mechanical integrity, low electrical resistance, and water-scavenging or acid-scavenging capability when used in a lithium battery. The water-scavenging or acid-scavenging capability results from the presence of functional groups that react with water or acid in the battery, thereby improving battery performance through the elimination of parasitic side reactions. The battery separator preferably includes a microporous polymer matrix throughout which the water-scavenging or acid-scavenging groups are dispersed.
In one preferred embodiment, the battery separator includes a first polyolefin that provides sufficient mechanical integrity to form a freestanding film and a second polyolefin that has chemically attached reactive functional groups that effect water or acid removal. A preferred first polyolefin is UHMWPE, and a preferred second polyolefin contains chemically attached anhydride groups.
In a preferred embodiment, the first polyolefin, second polyolefin, and a plasticizer are processed at an elevated temperature and extruded to yield a thin film. Subsequent removal of the plasticizer by an extraction process creates passageways that provide overall fluid permeability to the resulting separator.
Additional objects and advantages of this invention will be apparent from the following detailed description of the preferred embodiments, which proceeds with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram depicting a battery separator throughout which water-scavenging or acid-scavenging functional groups are dispersed.
FIG. 2 is a schematic diagram depicting a multilayer electrode assembly for use in a lithium-ion battery.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In accordance with the present invention, a battery separator for use in a lithium battery includes a polyolefin with chemically attached water-scavenging or acid-scavenging reactive functional groups that scavenge or effectively remove water or acid from the lithium battery, thereby improving battery performance. The reactive functional groups remove water or acid from the lithium battery by reacting with the water and/or acid in the battery to chemically remove it from the electrolyte.
An exemplary battery separator is depicted in FIG. 1 , which is a schematic diagram depicting water-scavenging or acid-scavenging reactive functional groups 2 distributed throughout a polymer matrix 4 of a microporous web 6 . During battery operation, web pores 8 are filled with electrolyte (not shown). Water-scavenging or acid-scavenging reactive functional groups 2 are dispersed throughout polymer matrix 4 of web 6 , but are primarily functional at the surfaces of web pores 8 . Thus FIG. 1 shows water-scavenging reactive functional groups 2 existing in web pores 8 .
Polymer matrix 4 preferably includes a first polyolefin and a second polyolefin. The first polyolefin provides sufficient mechanical integrity to form a film with freestanding characteristics, and the second polyolefin has chemically attached reactive functional groups that effect water or acid removal. “Freestanding” refers to a film having sufficient mechanical properties to permit manipulation such as winding and unwinding of the film. The terms “film” and “web” are used interchangeably throughout this patent application.
Various first polyolefins may be used in connection with the formation of the polymer matrix of the battery separator. Preferred first polyolefins include polypropylene, polyethylene (PE), and poly-4-methyl-1-pentene. Preferred types of PE include low density polyethylene (LDPE), linear low density polyethylene (LLDPE), high density polyethylene (HDPE), UHMWPE, low molecular weight PE (LMWPE), and combinations thereof. Preferably one or more of UHMWPE, LDPE, LLDPE, HDPE, or LMWPE are combined. More preferably, UHMWPE is combined with one or more of HDPE, LDPE, or LLDPE. A preferred UHMWPE incorporated into the film is one having an intrinsic viscosity of at least 10 deciliters/gram and preferably greater than about 20 deciliters/gram. Current commercially available UHMWPEs have an upper limit of intrinsic viscosity of about 40 deciliters/gram.
Various second polyolefins may be used in connection with the formation of the polymer matrix of the battery separator. The second polyolefin is preferably an anhydride-containing polymer, but may be any polyolefin that is compatible with the components in a lithium or lithium-ion battery and that chemically reacts with the water or acid in a battery to effectively remove the water or acid from the battery. Exemplary water-scavenging and acid-scavenging materials include chemically modified polyolefins. An exemplary commercially available water-scavenging and/or acid-scavenging materials is Integrate™ NE 556-P35, manufactured by Equistar Chemical Company.
While various processes known to those of skill in the art may be used to create the battery separator of the present invention, the “wet” method is preferred. The “wet” method involves combining a first polyolefin, a second polyolefin that includes water-scavenging reactive functional groups, and any other desired ingredients with a liquid, non-volatile plasticizer. The resulting mixture or slurry is injected into the feed port of a twin-screw extruder and subjected to elevated temperatures and shear. The mixture or slurry is extruded through a die, and sufficient plasticizer is extracted from the resulting film to form a microporous separator. An example of this method is as follows:
EXAMPLE
UHMWPE (37.5 kg, GUR™ 4120, manufactured by Ticona), HDPE powder (25 kg, Alathon™ L5005, less than 35 mesh, manufactured by Equistar), lithium stearate (0.72 kg, manufactured by Norac), antioxidant (0.59 kg, Irganox™ B215, manufactured by Ciba), and a plasticizer (111.1 kg, Hydrocal™ 800, manufactured by Calumet) were blended together in a Ross VMC-100 mixer. Maleic anhydride-modified polyolefin powder (0.027 kg, NE 556 P35, manufactured by Equistar) and additional plasticizer (0.91 kg) were added to 4.5 kg of the above mixture to form a 30% w/w polymer slurry. This slurry was pumped into a 40 mm twin screw extruder (manufactured by Betol) at a rate of approximately 5.4 kg/hr while a melt temperature of approximately 208° C. was maintained. The extrudate passed through a melt pump (37 rpm; 3 cc/rev) that fed a 49.5 mm diameter annular die having a 1.9 mm gap. The extrudate was inflated with air to produce a 300 mm neck length and a biaxially oriented film with a 356 mm layflat that was passed through an upper nip at 305 cm/min. A 100 mm×200 mm sample was cut from the plasticizer-filled sheet and restrained on four sides in a metal frame. The restrained sample was fully extracted in a trichloroethylene (TCE) bath and dried in a circulating air oven at 80° C. The resulting UHMWPE-based separator had 62% porosity and a thickness of 26.7 micrometers.
A preferred plasticizer is a nonevaporative solvent for the first and second polyolefins and is preferably liquid at room temperature. The plasticizer has little or no solvating effect on the polyolefins at room temperature; it performs its solvating action at temperatures at or above the softening temperature of the polyolefins. For UHMWPE, the solvating or gelling temperature would be above about 160° C., and preferably in the range of between about 160° C. and about 240° C. Exemplary suitable plasticizers include paraffinic oil, naphthenic oil, aromatic oil, or a mixture of two or more such oils. Exemplary suitable commercial processing oils include Hydrocal™ 800, manufactured by Calumet, oils sold by Shell Oil Company (such as ShellFlex™ 3681, Gravex™ 41, and Catnex™ 945), oils sold by Chevron Oil Company (such as Chevron 500R), and oils sold by Lyondell Oil Company (such as Tufflo™ 6056). In some cases, it is desirable to select the processing oil such that any residual oil in the polymer sheet after extraction is electrochemically inactive.
Preferred solvents for use in extracting the processing oil from the film are not deleterious to the functional groups contained in the polymer matrix and have a boiling point that makes it practical to separate the solvent from the plasticizer by distillation. Exemplary solvents include 1,1,2 trichloroethylene, perchloroethylene, 1,2-dichloroethane, 1,1,1-trichloroethane, 1,1,1-trichloroethane, TCE, methylene chloride, chloroform, 1,1,2-trichloro-1,2,2-trifluoroethane, isopropyl alcohol, diethyl ether, acetone, hexane, heptane, and toluene.
Exemplary additional ingredients incorporated into the UHMWPE web include antioxidants, colorants, pigments, residual plasticizer or processing oil, waxes, lubricants, other polymers, fillers (e.g., silica, alumina, and boron nitride), and processing aids.
The practice of the invention is not limited to a specific separator composition, geometry, or thickness. For example, the separator may be of a monolayer or multi-layer geometry. One exemplary multi-layer separator geometry involves positioning each of two PP films adjacent a PE film. While not limited to a specific thickness, exemplary battery separators in accordance with the present invention have a thickness ranging from about 8 micrometers to about 50 micrometers, which falls within the preferences of lithium and lithium-ion battery manufacturers.
A preferred implementation of the battery separator of the present invention is the inclusion of the microporous separator in a multilayer electrode assembly for use in a lithium or lithium-ion battery. The use of the battery separator of the present invention in a lithium-ion battery is depicted in FIG. 2 . Lithium-ion batteries convert chemical energy to electrical energy. The multilayer electrode assembly 12 depicted in FIG. 2 includes a negative electrode (anode) 14 , a separator 16 , a positive electrode (cathode) 18 , and current collectors (not shown). An operational lithium-ion battery includes an ionically conductive electrolyte, which is not shown in FIG. 2 , and a container 20 that surrounds anode 14 , separator 16 , cathode 18 , and the current collectors. A preferred polyolefin film has sufficient porosity to allow the electrolyte to rapidly wick through it.
A wide variety of electrochemically active materials can be used to form anode 14 and cathode 18 , as is commonly known in the art. Exemplary cathodes include lithium nickel oxide, lithium cobalt oxide, and lithium manganese oxide as well as any type of hybrid lithium oxide, e.g., lithium nickel cobalt oxide. Exemplary preferred anodes are carbon-based anodes including crystalline or amorphous carbonaceous materials in the form of fiber, powder, or microbeads, natural or synthetic graphite, carbon black, coke, mesocarbon microbeads, or activated carbon.
There are two types of electrolyte systems commonly used in lithium-ion batteries. The first type of commonly used electrolyte system is a liquid electrolyte system in which a liquid electrolyte is used to provide sufficient ionic conduction between electrodes that are packaged in a cylindrical or prismatic metal can. The second type of commonly used electrolyte system is a gel electrolyte system in which a gel electrolyte is sandwiched between the electrodes. Either type of electrolyte system, or any combination thereof, may be implemented in the battery of the present invention.
It will be obvious to those having skill in the art that many changes may be made to the details of the above-described embodiments without departing from the underlying principles of the invention. The scope of the present invention should, therefore, be determined only by the following claims.
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A battery separator having a thermal shutdown mechanism and exhibiting excellent mechanical properties and low electrical resistance includes a water-scavenging and/or acid-scavenging material having reactive functional groups that chemically react with water or acid in the battery to remove the water or acid and thereby improve battery performance. The battery separator preferably includes a first polyolefin providing mechanical integrity and a second polyolefin including the water-scavenging or acid-scavenging reactive functional groups. The battery separator is preferably a microporous film including a polymer matrix throughout which the water-scavenging or acid-scavenging material is dispersed.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This is a continuation-in-part of international application PCT/EP99/05862, filed Aug. 12, 1999, the contents of which are fully incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The present invention is in the field of polymers containing basic groups and ion-exchange groups. The invention relates in particular to methods for lateral chain modification of aryl main chain polymers with aromatic ketones and aldehydes containing basic nitrogen (N) groups and to the polymers made according to the methods.
RELATED ART
[0003] A) Polymers Modified with Basic N
[0004] There are still relatively few basic N-modified polymers on the market, the most important of which are mentioned below:
[0005] poly(4-vinyl pyridine), poly-2-vinyl pyridine) and copolymers.
[0006] These two polymers are commercially available, also as block copolymers with polystyrene. They are used for example as pre-stages for anion exchange membranes (Reiner, Ledjeff 1 , Gudernatsch, Krumbholz 2 ) or complexed with Schiff's bases containing cobalt for selective oxygen permeation 3 . The drawback with this class of polymer is the tertiary C—H-bond in the polymer main chain, which is susceptible to oxidation.
[0007] Polybenzimidazols
[0008] Polybenzimidazols are a class of polymers which have considerable chemical and mechanical stability. Many types of polybenzimidazols (fully and partly aromatic) have already been synthesised and examined 4 . However, only a few types are produced commercially, of which the most important is the polymer PBI (poly[(2,2-m-phenylene)-5,5′-bibenzimidazol) produced by Celanese under the commercial name CELAZOLE. This polymer is used, inter alia, in the form of low-flammability textiles 5 for the Fire Brigade. The drawbacks with this polymer are that it is difficult to dissolve in organic solvents and so has poor working properties. In addition, this polymer is very expensive.
[0009] Polyethylene imine
[0010] Polyethylene imine is used in organic chemistry and biochemistry as a precipitating agent for proteins6. The advantage of this polymer is that by virtue of its highly hydrophilic nature (1 N on 2 C), it is water soluble and therefore, in its pure form, will not form any resistant membranes. Furthermore, by virtue of its purely aliphatic structure, it is not very chemically stable.
[0011] B) Anion Exchange Polymers and Membranes
[0012] The commercial anion exchange polymers and membranes can be divided into two main categories:
[0013] anion exchange polymers which are produced by reaction of chlorinated 7 or bromomethylated 8 polymers with tertiary amines. The drawback with this reaction is the carcinogenic nature of the halomethylation reaction and the lack of chemical stability of the aromatic-CH 2 —NR 3 +grouping.
[0014] anion exchange polymers produced by the alkylation of tertiary N, for example of poly(vinyl pyridine) 1,2,9 with halogen alkanes 1,2 . The disadvantage with this reaction is that only very few commercial polymers with tertiary N are available (see above) and thus the range of membrane properties to be achieved is limited. The drawback with poly(vinyl pyridine)s is limited chemical stability (see above).
[0015] C) Cation Exchange Polymers Sulphonated in the Lateral Group
[0016] There are very few commercial polymers and membranes of this type. The most important are:
[0017] nafion 10
[0018] This polymer has a perfluoralkyl main chain and a perfluorether lateral chain at the end of which hangs a sulphonic acid group. This polymer is used in applications which require great chemical membrane stability, for example, in membrane fuel cells 11 . The disadvantage of this polymer is its high price ($800/sq.m) and complicated production process 10 .
[0019] poly-X 2000 12
[0020] This polymer consists of a poly(phenylene) main chain and an aryl lateral chain. The precise name of this polymer is poly(oxy-1,4-phenylene-carbonyl-1,4-phenylene). This polymer is sulphonated 12 only at the end of the lateral chain. Reportedly 12 , this polymer in the sulphonated form has good proton conductivity levels even at temperatures in excess of 100° C. at which the proton conductivity of sulphonated poly(ether ether ketone) (PEEK) drops markedly. This property could be brought out by a better association of the sulphonic acid groups in the poly-X 2000, since the sulphonic acid groups are in the lateral chain in the case of the poly-X 2000—in the sulphonated PEEK, the sulphonic acid groups are in the main chain and consequently, on account of the rigidity of the PEEK main chain, they associate less readily. A drawback with this polymer is its poorer thermal stability compared with sulphonated PEEK 12 and the fact that it is not commercially available.
SUMMARY OF THE INVENTION
[0021] The invention is directed to:
[0022] (1) A method for the lateral chain modification of engineering aryl main chain polymers with arylene-containing basic N-groups by the addition of aromatic ketones and aldehydes containing tertiary basic N-groups (such as for example tertiary amine, pyridine, pyramidine, and triazine) to the metallized polymer.
[0023] (2) Lateral chain modified polymers obtainable by the methods of the invention, whereby the lateral chain contains at least one aromatic group which carries a tertiary basic N.
[0024] (3) A method for quaternizing the tertiary N of the modified polymers obtainable according to the invention with halogen alkanes in order thus to incorporate anion exchanger groups into the lateral chain modified polymer.
[0025] (4) Engineering aryl main chain polymers carrying in the lateral chain anion exchanger functions and obtainable by the methods of the invention.
[0026] (5) A method for the lateral chain modification of engineering main chain polymers with arylene-containing basic N groups by the following reaction of aromatic carboxylic acid Ar—COOR′ containing tertiary basic N groups (such as for example tertiary amine, pyridine, pyramidine, and triazine) with the metallized polymer P—Me:
[0027] (6) Lateral chain modified polymers obtained by the methods of the invention in which the side chain contains at least one aromatic group which carries a tertiary basic N.
[0028] (7) A method of quaternizing the tertiary N of the modified polymers obtained by the methods of the invention with halogen alkanes to incorporate anion exchanger groups into the lateral chain modified polymer.
[0029] (8) Engineering aryl main chain polymers carrying in the lateral chain anion exchanger functions obtainable by the methods of the invention.
[0030] (9) A method for the lateral chain modification of engineering aryl main chain polymers with aromatic groups containing sulphonic acid radicals by the following sequence of reactions:
[0031] (9a) Reaction of the aromatic carboxylic acid ester Ar—COOR′ or carboxylic acid halide Ar—COHal with the metallized polymer P—Me:
[0032] (9b) Controlled electrophilic sulphonation of the lateral group with sulphuric acid SO 3 /P(O)(OR) 3 , CISO 3 H, or other sulfonating reagent. The lateral group is in this case so selected that its reactivity for sulphonation is substantially higher than the reactivity of the polymer main chain for sulphonation.
[0033] (10) Engineering aryl main chain polymers which only carry sulphonic acid functions in the lateral chain, obtainable by the methods of the invention.
[0034] (11) Membranes of the polymers obtainable according to the present invention, in which the membranes may be unvulcanised or covalently cross-linked.
[0035] (12) A method of producing acid-based blends/acid-based blend membranes from the basic polymers of the invention with polymers containing sulphonic acid, phosphonic acid or carboxyl groups.
[0036] (13) A method of producing acid-based blends/acid-based blend membranes from the basic polymers of the invention with the polymer of the invention containing sulphonic acid groups.
[0037] (14) Acid-based blends/acid-based blend membranes obtainable by the methods of the invention, whereby the blends/blend membranes may in addition be covalently cross-linked.
[0038] (15) Use of the ion exchange polymers of the invention in the form of membranes in membrane processes such as in polymer electrolyte membrane fuel cells (PEFC), direct methanol fuel cells (DMFC) and electrodialysis.
[0039] (16) Use of hydrophilic polymers of the invention containing the basic N in the lateral group in the form of membranes in dialysis and in reversed osmosis, nanofiltration, diffusion dialysis, gas permeation, pervaporation and perstraction.
[0040] For many applications in membrane technology (reversal osmosis, nanofiltration, micro- and ultrafiltration, electrodialysis, diffusion dialysis, membrane electrolysis, membrane fuel cells), hydrophilic or chemically stable polymers containing ion exchange groups are needed. However, these polymers are only commercially available in limited amounts. Even today, in some cases vinyl polymers with limited chemical stability are still being employed in the above-mentioned applications. Furthermore, the range of the properties of these commercial polymers is not very great.
[0041] As a result of this invention, aryl main chain polymers and membranes which are modified with basic nitrogen in the lateral group have become available. These polymers and membranes are hydrophilic and have very good thermal and mechanical stability. Furthermore, this invention provides chemically stable cation and anion exchange membranes which additionally, by reason of the presence of the ion exchange groups in the lateral chain, display a greater degree of freedom for forming ion exchange group associates than if the ion exchange groups were present in the polymer main chain.
[0042] In particular, the invention is directed to a method for producing engineering aryl main chain polymers having aryl-containing basic N-groups having the general formula
[0043] wherein P is a polymer with the repeating units
[0044] wherein R 3 is hydrogen, alkyl or aryl,
[0045] and said units R 1 and/or R 2 are linked by at least one group selected from
[0046] R 7 is an aromatic group containing tertiary basic N,
[0047] R 8 is hydrogen, alkyl or aryl, which optionally contains tertiary basic N,
[0048] X is hydrogen or an alkyl group,
[0049] comprising
[0050] a) reacting metallized polymer P—Me, wherein Me is Li or Na, with an aromatic ketone or aldehyde containing tertiary basic N-groups and having the general formula
[0051] to give an intermediate product of formula:
[0052] (b) protonating with water or etherifying with an alkyl halide.
[0053] The invention is also directed to a method for producing an engineering aryl main chain polymer having aryl-containing basic N-groups, comprising reacting a metallized polymer P—Me described above with an aromatic carboxylic acid derivative having tertiary basic N-groups of formula
[0054] wherein R 10 is an aromatic group containing tertiary basic N-groups and
[0055] Y is a halogen or —O—R 11 , wherein R 11 is an alkyl group or an aryl group.
[0056] The invention is also directed to a method for producing an engineering aryl main chain polymers having aryl-containing quaternary N-groups, comprising quarternizing the engineering aryl main chain polymers having aryl-containing basic N-groups with one or more halogen monoalkanes.
[0057] The invention is also directed to a method for producing engineering aryl main chain polymers having aryl-containing quaternary N-groups, comprising quarternizing and covalently cross-linking the engineering aryl main chain polymers having aryl-containing basic N-groups with a mixture of halogen mono- and halogen dialkanes
[0058] The invention is also directed to a method for producing engineering aryl main chain polymers having aromatic sulphone acid groups, comprising reacting an engineering aryl main chain polymer having aryl-containing basic N-groups with a sulphonating agent.
[0059] The invention is also directed to a method for producing a polysulphone having sulphonated aromatic side chains and having the general formula
[0060] comprising metallizing polysulphone PSU Udel® with lithium to give, for example, a lithiated polymer of the formula
[0061] and reacting with an aromatic carboxylic acid derivative of the formula
[0062] wherein Z is a halogen, and
[0063] reacting the reaction-product with sulphuric acid.
[0064] The invention is also directed to a method for producing anion exchange polymers, comprising reacting metallized polymers P—Me described above with diaromatic ketones having tertiary N-groups and then oxidizing the polymer in dilute mineral acid in solution or dispersion by the use of an oxidation agent. A particularly preferred oxidizing agent is air in an acid solution.
[0065] The invention is also directed to a method for producing polymer membranes, comprising dissolving the polymers of the invention in a dipolar aprotic solvent, applying the polymer solution to a backing as a thin layer, and removal of the solvent, e.g. by evaporation. Examples of such backings include a glass plate, a woven fabric or a fleece.
[0066] The invention is also directed to a method for producing acid-base blend membranes, comprising mixing the polymers of the invention with polymers in acid or salt form containing sulphonate, phosphonate or carboxylate groups in a dipolar aprotic solvent, applying the polymer solution to a backing as a thin layer, and removing the solvent.
[0067] The invention also relates to methods of using the membranes obtained according to the invention in membrane processes, particularly in polymer electrolyte membrane fuel cells, direct methanol fuel cells, diffusion dialysis and electrodialysis. Particular uses include dialysis, reversal osmosis, nanofiltration, gas permeation, pervaporation and perstraction.
BRIEF DESCRIPTION OF THE FIGURES
[0068] [0068]FIG. 1 depicts the reaction of lithiated PSU with benzaldehyde, benzophenone and acetone 13 . R 1 ═H, R 2 =phenyl; benzaldehyde; R 1 ═R 2 =phenyl: benzophenone; R 1 —R 2 ═CH 3 : acetone.
[0069] [0069]FIG. 2 depicts aldehydes and ketones which can be added to lithiated PSU after the reaction shown in FIG. 1.
[0070] [0070]FIG. 3 depicts the presumed oxidation reaction of the adduct of 4,4′-bis-diethylamino)-benzophenone to lithiated PSU forming a chromophoric group on the PSU.
[0071] [0071]FIG. 4 depicts the normal reaction of Li organic compounds with carboxylic acid esters 16 .
[0072] [0072]FIG. 5 depicts the reaction of lithiated PSU with isonicotinic acid ethyl ester.
[0073] [0073]FIG. 6 depicts the sequence of reactions for obtaining polysulphone PSU Udel® sulphonated in the aromatic lateral chain.
[0074] [0074]FIG. 7 depicts the reaction product of lithiated PSU with N,N-dimethyl amino benzaldehyde.
[0075] [0075]FIG. 8 depicts the reaction product of lithiated PSU with bis-(N,N-diethylamino)benzophenone.
[0076] [0076]FIG. 9 depicts the etherification of the PSU Li alcoholate.
[0077] [0077]FIG. 10 depicts the structural formula of the reaction product of lithiated PSU with di(2-pyridyl)ketone.
[0078] [0078]FIG. 11 depicts the product of reaction of lithiated PSU with isonicotinic aced ethyl ester.
[0079] [0079]FIG. 12 depicts the product of reaction of lithiated PSU with N,N-dimethyl amino benzoic acid ethyl ester.
[0080] [0080]FIG. 13 depicts groups of aryl main chain polymers usable for the method according to the invention.
[0081] [0081]FIG. 14 depicts a reaction according to the invention and involving metallized polymers with ketones or aldehydes containing aromatic tertiary basic nitrogen (Ar=aryl main chain polymer, see FIG. 13; Me═Li, Na; R 1 =aromatic group containing basic tertiary N; R 2 ═H or alkyl or aryl group, which may additionally contain tertiary basic N.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0082] The description of the invention is sub-divided into five parts for reasons of clarity:
[0083] a. Basic N-modified polymers obtained by an addition reaction to lithiated polymers.
[0084] b. Basic N-modified polymers obtained by a substitution reaction with lithiated polymers.
[0085] c. Anion exchange polymers and membranes.
[0086] d. Cation exchange polymers sulphonated in the lateral group.
[0087] e. Acid-based blends and acid-based blend membranes from polymers a or b with any desired sulphonated polymers or with the cation exchange polymers d.
[0088] a) Basic N-modified Polymers by Addition Reaction to Lithiated Polymers
[0089] Particular aryl main chain polymers that can be used according to the present invention include, without limitation:
[0090] polyether sulphone PSU Udel®: R 2 (R 3 ═CH 3 )—R 4 —R 1 (R 3 ═H)—R 5 —R 1 —R 4 ,
[0091] polyether sulphone PES Victrex®: R 1 —R 5 —R 1 —R 4 ,
[0092] polyphenyl sulphone PPhSU Radel R®: R 1 (R 3 ═H)—R 1 (R 3 ═H)—R 4 —R 1 (R 3 ═H)—R 5 —R 1 —R 4 , and
[0093] polyether ether sulphone PEES Radel A®: [R 4 —R 1 (R 3 ═H)—R 4 —R 1 (R 3 ═H)—R 5 —R 1 (R 3 ═H)] n —[R 4 —R 1 (R 3 ═H)—R 5 —R 1 (R 3 ═H)] m , n/m=0,18.
[0094] Guiver reports PSU hydrophilically modified in the lateral chain via a metallizing reaction and subsequent addition of selected aldehydes and ketones, forming PSU 13 modified with OH groups in the lateral chain (FIG. 1). The following degrees of substitution were achieved: benzaldehyde 1.9, benzophenone 1.0, acetone 0.5.
[0095] Surprisingly, now, it has been found that according to the reaction in FIG. 1, aromatic ketones and aldehydes which contain tertiary N can be added to lithiated PSU. Examples of such basic aromatic ketones which can be added include (see FIG. 2) 2,2′bipyridyl ketone, 4,4′-bis(dimethyl amino)-benzophenone (Michler's ketone) and 4,4′-bis(diethyl amino)-benzophenone. Examples of basic aromatic aldehydes include (see FIG. 2) 4-dimethyl amino benzaldehyde, 4-diethyl amino benzaldehyde and pyridine-2-aldehyde, pyridine-3-aldehyde, pyridine-4-aldehyde.
[0096] Where this reaction is concerned, the degrees of substitution are dependent upon the size of the basic aromatic compound. Thus, with the stetically hindered ketones 2,2-bipyridyl ketone, 4,4′-bis(dimethyl amino)-benzophenone (Michler's ketone) and 4,4′-bis(diethyl amino)-benzophenone, degrees of substitution of about 1 are reached while degrees of substitution of up to 2 can be achieved with the above-mentioned less sterically hindered aldehydes.
[0097] Upon synthesis of the product of addition of 4,4′-bis(diethyl amino)-benzophenone to lithiated PSU, it was surprisingly found that the substituted polymer was coloured, the colour deepening from pale green to very dark green in time, by exposure to the air. This is probably attributable to oxidation of the PSU addition product by atmospheric oxygen according to the reaction shown in FIG. 3. Presumably, a triphenyl methane dye 14 is produced. This reaction points away to chromophoric groups which can be bonded on lithiable polymers. These chromophoric groups are positively charged which means they constitute anion exchanger groupings since the compensating ions, e.g. Cl − , are inter-changeable. Since the compensating ions are interchangeable, the oxidised basic polymer displays ion conductivity which it was possible to prove experimentally. Since the positive charge is distributed mesomerically over the system:
[0098] These anion exchange groups are very stable in comparison with normal anion exchange groups.
[0099] If it is intended to prevent oxidation of the PSU addition product, the Li-alcoholate intermediate compound which forms during the addition reaction can be captured with alkyl halides Alk-Hal, forming the ether PSU-C(C 1 R 2 )-OAlk. Thus, the addition compound becomes more oxidation stable than the addition compound with the free OH— group.
[0100] b) Polymers Modified by Basic N by Substitution Reaction with Lithiated Polymers
[0101] If low molecular aromatic carboxylic acid esters are caused to react with Li-organic compounds, then in most cases the lithium salts of tertiary alcohols are obtained (FIG. 4) 16 .
[0102] Surprisingly, it has been found that the reaction of basic compounds such as for example isonicotinic acid ethyl ester and N,N-dimethyl amino benzoic acid ethyl ester with lithiated PSU can, under the selected conditions (low temperature, low polymer concentration in the solution of the lithiated PSU, excess of a basic compound) can be arrested at the ketone stage (FIG. 5).
[0103] In this way, it is possible form lithiated polymers to produce such polymers as are modified with basic N-groups (tertiary N such as pyridyl or dialkyl amino groups) in the aromatic lateral chain. By virtue of its aromatic nature and by reason of the bonding on the polymer main chain via a carbonyl function, the lateral chain becomes very oxidation stable. The synthesised polymers which contain tertiary N can, in a further step, be converted by N-quaternization into oxidation stable anion exchange polymers (see c)).
[0104] c) Anion Exchange Polymers and Membranes
[0105] The above-mentioned polymers which are modified with basic tertiary N in the aromatic lateral chain can, now, be reacted by means of conventional processes 15 to produce anion exchange polymers and membranes, whereby even anion exchange membranes are accessible by the following method: a solution of the lithiated polymer modified with tertiary-N in the lateral group is produced in a dipolar-aprotic solvent (for example, NMP, DMAc, DMF, DMSO, sulpholane, etc.). Halogen alkanes and halogen dialkanes in the desired molar ratio are then added to the solution in order to generate the desired density of cross-linking and the solvent is evaporated off at elevated temperature. During membrane formation, the tertiary-N groups are quaternized to give anion exchange groups, the dihalogen alkanes at the same time forming a covalent network in the membrane.
[0106] d) Cation Exchange Polymers which are Sulphonated in the Lateral Group
[0107] On the basis of the reaction presented in b) (reaction of an aromatic carboxylic acid ester with lithiated aryl polymer with the bonding of an aromatic lateral group to the aryl main chain polymer via a carbonyl group), aryl main chain polymers which are sulphonated in the lateral group become accessible, subject to the aromatic lateral group being more easily electrophilically sulphonatable than the polymer main chain. In order to achieve this, the aromatic hydrocarbon present in the lateral group must have the greatest electron density of all the aromatic rings of the polymer. A reaction to obtain an aryl main chain polymer sulphonated in the aromatic lateral chain is shown in FIG. 6. In the case of the PSU Udel® sulphonated in the aromatic lateral chain, the aromatic hydrocarbon at the end of the aromatic lateral chain has the greatest electron density of the entire molecule. For this reason, this aromatic hydrocarbon is sulphonated and in fact in the p-position in relation to the ether bridge since the o-position (also electronically possible) is sterically hindered in relation to the ether bridge.
[0108] e) Acid-based Blends and Acid-based Blend Membranes from the Polymers a or b Polymers Sulphonated as Desired or with the Cation Exchange Polymers d
[0109] The newly obtained polymers listed in sub-paragraphs a, b and d as well as any sulphonated polymers can be combined to produce new acid-based blends and acid-based blend membranes. Examples of polymers having sulfonate groups include sulfonated polystyrene, poly(anethoicsulfonic acid), sulfonated polyesters (see, e.g. U.S. Pat. Nos. 4,360,607 and 5,750,605) and polyvinylsulfate. Examples of polymers having carboxyl groups include polyacrylic acid and copolymers thereof. The location of the acid and basic groups at the end of the aromatic lateral chain provides a way to improve the association of the ion exchange groups in the blends since the position of the acid and basic groups at the end of the lateral group is less sterically hindered than if these groups were in the polymer main chain. Improved association of acid and basic groups can result in an increased local concentration of ion exchange groups in the polymer matrix and thus a higher level of proton conductivity even at relatively low concentrations of ion exchange groups compared to rigid aryl main chain polymers modified with acid and basic groups in the main chain. The morphology of the perfluorinated ion exchange polymer Nafion in which the sulphonic acid groups are strongly associated (clustered) 10 on account of the extremely hydrophobic perfluorinated backbone, can consequently be substituted by such new acid-based blends. In addition to the ionic cross-linking by the polysalt formation:
P—SO 3 H+P′—NR 2 →P—SO 3− + R 2 NH—P′
[0110] due to the mixture of acid with basic polymers in the solvent, dihalogen alkanes may be added which, during membrane formation:
P′—NR 2 +Hal—(CH 2 ) x —Hal+R 2 N—P′→P′—NR 2 +—(CH 2 ) x —R 2 N + —P′
[0111] with quaternization of the tertiary N.
[0112] The invention covers new polymers and membranes which are chemically stable on account of the aromatic lateral chain and which can be further modified under control:
[0113] By quaternizing the basic N with alkyl halides, new anion exchange polymers and membranes can be produced which, by reason of the direct bonding of the basic N on the aromatic lateral chain, become chemically more stable than commercial anion exchange polymers and membranes. Due to the possibility of using dihalogen alkanes, the anion exchange polymer membranes can furthermore be covalently cross-linked at the same time.
[0114] The synthesis of polymers with aromatic lateral groups which are sulphonated in the aromatic lateral group can improve the association of the sulphonic acid groups in the polymer matrix and thus lead to higher levels of proton conductivity even at relatively low ion exchange group concentrations.
[0115] The acid-base blends and acid-base blend membranes according to the invention may display a better ion exchange group association than acid-base blends and acid-base blend membranes, in which the acid and basic groups are present in the polymer main chain, since the lateral groups are more movable than the polymer main chain. In addition to the ionic cross-linking due to the polysalt formation, these blends and blend membranes can, by covalent cross-linking, be further stabilised in terms of swelling and thus mechanical stability.
[0116] Useful aryl groups are C 6-14 aryl, especially C 6-10 aryl. Typical C 6-14 aryl groups include phenyl, naphthyl, phenanthrenyl, anthracenyl, indenyl, azulenyl, biphenyl, biphenylenyl and fluorenyl groups.
[0117] Useful halo or halogen groups include fluorine, chlorine, bromine and iodine.
[0118] Useful alkyl groups include straight-chained and branched C 1 -10 alkyl groups, more preferably C1-6 alkyl groups. Typical C1-10 alkyl groups include methyl, ethyl, propyl, isopropyl, butyl, sec-butyl, tert-butyl, 3-pentyl, hexyl and octyl groups.
[0119] Useful mono halogen alkyl groups include C1-10 alkyl groups substituted by a fluorine, chlorine, bromine or iodine atom, e.g. methyl iodide, ethyl bromide, 1-propyl bromide and the like. Useful dihalogen alkyl groups include C2-10 alkyl groups substituted by two fluorine, chlorine, bromine or iodine atoms, e.g. 1,2-dichloroethane, 1,3-dibromopropane, 1,4-diiodobutane and the like.
[0120] Useful tertiary amino groups include —NR 1 R 2 , wherein R 1 and R 2 are C 1-10 alkyl groups as defined above, e.g. dimethylamino, diethylamino and the like.
[0121] Useful basic N-containing hetercyclic aromatic compounds include pyrrolyl, imidazolyl, pyrazolyl, pyridyl, pyrazinyl, pyrimidinyl, pyridazinyl, indolizinyl, isoindolyl, 3H-indolyl, indolyl, indazolyl, purinyl, 4H-quinolizinyl, isoquinolyl, oxazolyl, quinolyl, phthalzinyl, naphthyridinyl, quinozalinyl, triazinyl and thiazolyl.
[0122] Having now generally described this invention, the same will be understood by reference to the following examples which are provided herein for purposes of illustration only and are not intended to be limiting unless otherwise specified.
EXAMPLES
Example 1
Reaction of N,N-dimethyl Amino Benzaldehyde with Lithiated PSU
[0123] Batch:
[0124] 11.05 g PSF Udel P 1800 (0.025 mol) dried
[0125] 500 ml THF anhydrous
[0126] 5 ml n-BuLi 10 N (0.05 mol)
[0127] 10 g 4-dimethyl amino benzaldehyde (0.13 mol), dissolved in 20 ml THF
[0128] Procedure
[0129] Under barrier gas, fill the THF into the reaction vessel. Afterwards, the dried polymer is introduced with argon into the reaction vessel accompanied by stirring and thorough rinsing. Once the polymer has been dissolved, it is cooled to −65° C. in a strong argon flow. The polymer solution is then titrated with n-BuLi until a slight yellow/orange coloring indicates that the reaction mixture is now anhydrous. Afterwards, the 10 N n-BuLi is injected within 10 mins. Stirring follows for 30 mins. Afterwards, the solution of 4-dimethyl amino benzaldehyde in THF is injected. Stir until such time as the reaction mixture has lost its color. Maximum waiting time at −65° C. is 1 hour. Afterwards, the acetone cold bath is taken away and replaced by an ice bath. Allow to warm to 0° C. and stir for 1 hour at 0° C. Afterwards, the reaction mixture is precipitated in 2 liters isopropanol. Dry at 50° C. firstly in a diaphragm pump vacuum then in an oil pump vacuum. Afterwards, the polymer is ground, suspended in 500 ml methanol and dried once again in a vacuum at 50° C. The chemical structural formula of the modified PSU formed is shown in FIG. 7.
[0130] Elementary analysis and the 1 H-NMR spectrum of the polymer reveal a substitution degree of approximately 2 groups per PSU repetition unit.
Example 2
Reaction of bis(N,N-diethyl amino)benzophenone with Lithiated PSU
[0131] Batch:
[0132] 11.05 g PSU Udel P 1800 (0.025 mol), dried
[0133] 600 ml THF anhydrous
[0134] 3 ml n-BuLi 10 N (0.03 mol)
[0135] 25 g 4,4′-bis-diethyl amino benzophenone dissolved in 50 ml THF (0.077 mol)
[0136] Procedure:
[0137] Under barrier gas, fill the THF into the reaction vessel. Afterwards, the dried polymer is introduced with argon into the reaction vessel accompanied by stirring and thorough rinsing. Once the polymer has been dissolved, it is cooled to −30° C. in a strong argon flow. The polymer solution is then titrated with n-BuLi until a slight yellow/orange colouring indicates that the reaction mixture is now anhydrous. Afterwards, the 10 N n-BuLi is injected within 10 mins. Stirring follows for 50 mins. Afterwards, the solution of 44′-diethyl amino benzophenone is injected. Stir until such time as the reaction mixture has lost its colour, not more than 24 hours. Afterwards, a mixture of 20 ml isopropanol with 2 ml of water is injected into the reaction solution and afterwards warmed to room temperature. The polymer is precipitated in 2 liters of isopropanol, filtered off and washed with isopropanol. Afterwards, the polymer is stirred into 300 ml i-PrOH. Afterwards, it is filtered off again, suspended again in i-PrOH, stirred and filtered off. Afterwards, the polymer is added to 5 liters of water and stirred. After filtration, it is once again added to 5 liters of water and stirred again. Subsequently, a further filtration process follows and then washing to pH 7 and afterwards dried at 80° C. The chemical structural formula of the modified PSU formed is shown in FIG. 8.
[0138] Elementary analysis and the 1 H-NMR spectrum of the polymer disclose a substitution degree of approximately 1 group per PSU repetition unit. The polymer is colored green, a situation which can be attributed to partial formation of triphenyl methyl chromophores by oxidation accompanied by cleavage of the OH group (see FIG. 3). If the polymer is allowed to stand at elevated temperature in dilute acid, the colour deepens to a black-green. With 1 H— and 13 C-NMR, it was possible to show that the reaction of the reaction product 6.2 shown in FIG. 3 actually takes place: the 1 H and the 13 C signal of the OH proton, of which the position could be identified by H/D exchange as being recumbent with a chemical shift of 5.8 ppm ( 1 H-NMR) or a chemical shift of 85 ppm ( 13 C-NMR), had almost completely disappeared after the reaction products 6.2 had been stored in dilute acid at 60° C. with air having access.
[0139] Formation of the chromophoric group can be prevented by etherifying the OH group by a reaction of the PSU-Li-alkoxide with methyl iodide for example (FIG. 9). The oxidized reaction product 6.2 displays ion conductivity which can be attributed to the causes outlined hereinabove. To this end, films of the oxidised polymer were assessed by impedance spectroscopy in 0.5 N HCl with and without secondary HCl treatment.
[0140] Results:
Film thickness R a R sp Polymer film [μm] [Ω*sq.cm] [Ω*cm] 6.2 + secondary treatment 55 7.6 500 6.2 without secondary treatment 155 4.6 840
Example 3
Reaction of 2,2′-dipyridyl Ketone with Lithiated PSU
[0141] Batch:
[0142] 6.88 g PSU Udel P 1800 (0.01556 mol) dried
[0143] 400 ml THF anhydrous
[0144] 1.7 ml n-BuLi 10 N (0.017 mol)
[0145] 3.89 g di(2-pyridyl)-ketone (0.021 mol), dissolved in 20 ml THF
[0146] Procedure:
[0147] Under barrier gas, fill the THF into the reaction vessel. Afterwards, the dried polymer is introduced with argon into the reaction vessel accompanied by stirring and thorough rinsing. Once the polymer has been dissolved, it is cooled to −30° C. in a strong argon flow. The polymer solution is then titrated with n-BuLi until a slight yellow/orange colouring indicates that the reaction mixture is now anhydrous. Afterwards, the 10 N n-BuLi is injected within 10 mins. Stirring follows for 30 mins. Afterwards, the solution of di(2-pyridyl)-ketone is injected into THF.
[0148] Stir until the reaction mixture has lost its colour, at most 48 hours at −30° C.
[0149] Subsequently, inject a mixture of 10 ml isopropanol with 1 ml water into the reaction solution and allow to warm up to room temperature. Precipitate the polymer in 2 liters isopropanol, filter off and wash with isopropanol and methanol.
[0150] The precipitated polymer is filtered off again, dried and stirred in 100 ml MeOH. After-wards, it is filtered off again, suspended once again in MeOH, stirred, filtered off and dried at 80° C. The structural formula of the reaction product is shown in FIG. 10.
[0151] The degree of substitution of the modified PSU in terms of dipyridyl groups, determined by elementary analysis, amounts to about 0.85 per PSU repetition unit.
Example 4
Reaction of Isonicotinic Acid Ethyl Ester with Lithiated PSU
[0152] Batch:
[0153] 8.84 g PSU Udel P 1800 (0.02 mol), dried
[0154] 300 ml THF anhydrous
[0155] 4 ml n-BuLi 10 N (0.04 mol)
[0156] 10.5 ml isonicotinic acid ethyl ester (0.07 mol)
[0157] Procedure
[0158] Under barrier gas, fill the THF into the reaction vessel. Afterwards, the dried polymer is introduced with argon into the reaction vessel accompanied by stirring and thorough rinsing. Once the polymer has been dissolved, it is cooled to −30° C. in a strong argon flow. The polymer solution is then titrated with n-BuLi until a slight yellow/orange colouring indicates that the reaction mixture is now anhydrous. Afterwards, the 10 N n-BuLi is injected. Stirring follows for 50 mins. Afterwards, inject the isonicotinic acid ethyl ester and stir until the reaction mixture has lost its color, at most 24 hours at −30° C. Afterwards, inject the mixture of 20 ml isopropanol with 2 ml water into the reaction solution and allow to warm to room temperature. Precipitate the polymer in 2 ml isospropanol, filter off and wash with isopropanol. Afterwards, stir the polymer in 300 ml i-PrOH. Subsequently, filter off again, suspend once more in i-PrOH, stir and filter off. After filtration, add to 5 liters water again and stir afresh. Afterwards, filter off once more and afterwards dry at 80° C. The reaction product is shown in FIG. 11.
[0159] The degree of substitution of the modified PSU with 4-pyridyl carbonyl groups amounts to 1.65, determined by 1H-NMR and elementary analysis.
Example 5
Reaction of N,N-dimethyl Amino Benzoic Acid Ethyl Ester with Lithiated PSU
[0160] Batch:
[0161] 11.05 g PSU Udel P 1800 (0.025 mol), dried
[0162] 600 ml THF anhydrous
[0163] 5 ml n-BuLi 10 N (0.05 mol)
[0164] 48.32 g N,N-dimethyl amino benzoic acid ethyl ester, dissolved in 100 ml THF (0.25 mol)
[0165] Procedure:
[0166] Under barrier gas, fill the THF into the reaction vessel. Afterwards, the dried polymer is introduced with argon into the reaction vessel accompanied by stirring and thorough rinsing. Once the polymer has been dissolved, it is cooled to −60° C. in a strong argon flow. The polymer solution is then titrated with n-BuLi until a slight yellow/orange coloring indicates that the reaction mixture is now anhydrous. Afterwards, the 10 N n-BuLi is injected within 10 mins. Stirring follows for 50 mins. Afterwards, the solution of N,N-dimethyl amino benzoic acid ethyl ester is injected in THF. Stir for 10 mins. Then inject the mixture of 20 ml isopropanol with 2 ml water into the reaction solution and warm up to room temperature. Precipitate the polymer in 2 liters isopropanol, filter off and wash with isopropanol and methanol. The precipitated polymer is filtered off again, dried and stirred in 100 ml MeOH. Afterwards, it is filtered off again, suspended again in MeOH, stirred, filtered off and dried at 80° C. The result of elementary analysis shows a substitution degree of 0.75 p-N,N-dimethyl amino phenyl carbonyl groups per PSU repetition unit. As further tests have shown, the degree of substitution can be increased by a longer reaction time of the lithiated PSU with N,N-dimethyl amino benzoic acid ethyl ester. The reaction product of this reaction (with a p-N,N-dimethyl amino phenyl carbonyl group per PSU repetition unit) is shown in FIG. 12.
Example 6
Acid-base Blend Membrane of Reaction Product 6.2 with Sulphonated PSU
[0167] 4 g sulphonated PSU Udel® in the SO 3 Li form are dissolved in 25 g N-methyl pyrrolidinone. Afterwards, 1 g of the reaction product from reaction 6.2 (1.1 groups per PSU repetition unit) is added to the solution and stirred until dissolved. Afterwards, the very dark green solution is filtered off, de-gassed and applied as a thin film into a glass plate. The solution is then evaporated off at 120° C. Afterwards, the glass plate is placed in a bath with full desalinated water whereupon the polymer membrane becomes detached from the glass plate. Afterwards, the membrane is first treated in 10% sulphuric acid at 70° C. and then given a secondary treatment in completely desalinated water. Afterwards, the membrane is characterised.
Characterisation results: Ion exchange capacity: 1.35 meq SO 3 H/g Swelling (H 26 -form, RT): 33.14% Specific resistance (H + -form, RT) 27.6 Ωcm
Example 7
Acid-base Blend Membrane Consisting of Reaction Product 6.4 with Sulphonated PSU
[0168] 4 g sulphonated PSU Udel® in the SO 3 Li form are dissolved in 25 g N-methyl pyrrolidinone. Afterwards, 1 g of the reaction product of reaction 6.2 (1.65 groups per PSU repetition unit) is added to the solution and stirred until dissolved. Afterwards, the solution is filtered, de-gassed and applied as a thin film to a glass plate. The solvent is then evaporated off at 120° C. The glass plate is then laid in a bath with fully desalinated water, whereupon the polymer membrane becomes detached from the glass plate. The membrane is then given a secondary treatment at 70° C. firstly in 10% sulphuric acid and then in fully desalinated water. The membrane is then characterised.
Characterisation results: Ion exchange capacity: 1.09 meq SO 3 H/g Swelling (H + -form, RT): 24.6% Specific resistance (H + -form, RT): 21.2 Ωcm
Example 8
Acid-base Blend Membrane Consisting of Reaction Product 6.5 with Sulphonated PSU
[0169] 4 g sulphonated PSU Udel® in the SO 3 Li form are dissolved in 25 g N-methyl pyrrolidinone. Afterwards, 1 g of the reaction product from reaction 6.2 (0.75 groups per PSU repetition unit) is added to the solution and stirred until dissolved. Afterwards, the solution is filtered, de-gassed and applied as a thin film to a glass plate. Afterwards, the solvent is evaporated off at 120° C. The glass plate is then placed in a bath with fully desalinated water, whereupon the polymer membrane formed becomes detached from the glass plate. The membrane is then given a secondary treatment at 70° C. firstly in 10% sulphuric acid and then in fully desalinated water. Afterwards, the membrane is characterised.
Characterisation results: Ion exchange capacity: 1.11 met SO 3 H/g Swelling (H + -form, RT): 23.5% Specific resistance (H + -form, RT): 17.6 Ωcm
[0170] Literature
[0171] 1 Anion Exchange Membranes Consisting of Poly(vinylpyridine) and Poly(vinyl benzyl chloride) for Cr/Fe Redox Batteries A. Reiner, K. Ledjeff, Journal of Membrane Science 36: 535-540 (1988)
[0172] 2 Development of an Anion-Exchange Membrane with Increased Permeability forOrganic Acids of High Molecular Weight W. Gudernatsch, Ch. Krumbholz, H. Strathmann Desalination 79: 249-260 (1990)
[0173] 3 Membranes of poly(styrene-block-butadiene-block-styrene-graft-2-vinylpyridine) complexed with cobalt-containing schiff's bases for oxygen permeation G. -H. Hsiue, J. -M. Yang Die Makromolekulare Chemie ( Macromolecular Chemistry ) 192: 2687 2699 (1991)
[0174] 4 E. -W. Chloe, D. D. Choe, Polybenzimidazoles (Overview), in: Polymeric Materials Encyclopedia, Vol. 8, 5619-5683, CRC Press, New York, 1996
[0175] 5 Properties and Applications of Celanese PBI-Polybenzimidazole Fibre D. R. Coffin, G. A. Serad, H. L. Hicks, R. T. Montgomery Textile Research Journal 52(7): 466-72 (1982)
[0176] 6 Polyelectrolyte precipitation of beta-galactosidase fusions containing poly-aspartic acid tails J. Zhao, C. F. Ford, C. E. Glatz, M. A. Rougvie, S. M. Gendel J. Biotechnol. 14(304): 273-83 (1990)
[0177] 7 Novel Ion Exchange Membranes Based on an Aromatic Polysulfone P. Zschocke, D. Quellmalz Journal of Membrane Science 22: 325-332 (1985)
[0178] 8. Polysulfon-Based Interpolymer Anion Exchange Membrame A. Warshawsky, O. Kedem Journal of Membrane Science 53: 37-44 (1990)
[0179] 9 I. M. Khan, Vinylpyridine Polymers, in: Encyclopedia of Polymer Science and Engineering, Vol. 17, 567-577, Wiley-Interscience, New York, 1996
[0180] 10 Perfluorinated Ion-Exchange Polymers and Their Use in Research and Industry W. G. Grot Macromolecular Symposia 82: 161-172 (1994)
[0181] 11 Die reversible Membran-Brennstoffzelle (The reversible membrane fuel cell) Ledjeff, K.; Heinzel, A.; Mahlendorf, F.; Peinecke, V. Dechema Monographs, Vol. 128, VCH Verlagsgesellschaft 103-118 (1993)
[0182] 12 Proton conducting polymers derived from poly(etheretherketone) and poly(4-phenoxybenzoyl-1,4-phenylene) T. Kobayashi, M. Rikukawa, K. Sanui, N. Ogata Solid State Ionics 106: 219-225 (1998)
[0183] 13 Aromatic Polysulfones Containing Functional Groups by Synthesis and Chemical Modification M. D. Guiver Dissertation, Carletown University, Ottawa-Ontario, Canada (1987)
[0184] 14 Beyer/Walter, Lehrbuch der Organischen Chemie (Manual of Organic Chemistry), 19th Edition, S. Hirzel Verlag Stuttgart, 569f, 1981
[0185] 15 J. Goerdeler, Herstellung von quarternären Ammonium-verbindungen (Manufacture of Quaterniary Ammonium Compounds, Houben-Weyl, Methoden der organischen Chemie (Methods of Organic Chemistry), Vol. XI/2, Stickstoffverbindungen (Nitrogen Compounds) Georg Thieme Verlag, Stuttgart, S. 591 f (1958)
[0186] 16 U. Schöllkopf, Methoden zur Herstellung und Umwandlung von lithium-organischen Verbindungen (Methods of Manufacturing and Converting Lithium Organic Compounds) in: Houben-Weyl, Methoden der Organischen Chemie (Methods of Organic Chemistry), Vol. XIII/1, Metallorganische Verbindungen (Metal Organic Compounds), Georg Thieme Verlag, S. 185f (1970).
[0187] From the foregoing description, one skilled in the art can easily ascertain the essential characteristics of this invention, and without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various usages and conditions without undue experimentation. All patents, patent applications and publications cited herein are incorporated by reference in their entirety.
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A method for lateral chain modification of aryl main chain polymers with aromatic ketones or aldehydes containing tertiary basic N-groups is described. The modification can be accomplished via addition of an aromatic carboxylic acid or an acid derivative containing a tertiary amine moiety to a metallized polymer. The tertiary amines on the modified polymer can be converted to quaternary amines with halogen alkanes. Modification of the aryl main chain polymers with aromatic groups containing sulphonic acid radicals is also described. The polymers formed can be crosslinked and prepared for use in a wide variety of membrane technologies including ion exchange, dialysis, reverse osmosis, nanofiltration.
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TECHNICAL FIELD
[0001] The present invention has its application in the pharmaceutical field, especially in the field of pharmaceutical combinations and compositions comprising a lipase inhibitor, a phytoalexin and pharmaceutically acceptable excipients or carriers. The present invention also relates to a process for the manufacture of the pharmaceutical composition and the use of such composition for the preparation of a drug product useful in the treatment of overweight, obesity and related health problems.
BACKGROUND OF THE INVENTION
[0002] The World Health Organization (WHO) warns that in the world there are more than 1,600 million people with overweight and that number increases exponentially. Also according to the WHO, the number of obese people is more than 700 million.
[0003] Previously, it was considered that overweight or obesity were problems that only affected rich countries but the WHO estimates show that overweight and obesity are increasing exponentially in the low and middle income countries. This is due to several factors such as the widespread change of diet towards increased intake of calories, fats, salts and sugars, the trend towards the decrease of physical activity caused by the sedentary nature of the job, changing transportation media and the increase of urbanization.
[0004] In Mexico, according to official data, 70% of adults are overweight and even worse, the same percentage is recorded in children between 5 and 11 years old (4.5 million children). The care of people suffering from obesity in Mexico has grown considerably in recent years, in more than 60% since 2000, triplicating the percentage since 1980.
[0005] Obesity is a chronic and degenerative disease. In adults, overweight and obesity promote the development of diseases such as hypertension, diabetes mellitus, gout, stroke, heart disease and more. Some scientific research assure that the current childhood obesity will cause, in the coming years, further grow of the population of young adults with diabetes mellitus, hypertension, hyperlipidemia and many other problems related to excess body fat and sedentary lifestyles.
[0006] In the case of cardiovascular diseases, it has been observed that the risk of developing coronary disease increases by 20% in overweight people and 50% in obese people.
[0007] The risk of developing type 2 diabetes increases by 20% in overweight or obese people.
[0008] On the other hand, a body mass index (normal BMI 18.5-24.9) equal or greater than 25 is associated with a higher risk of suffering bone and hip fractures.
[0009] Compared with normal weight individuals, those who are overweight and obese have a higher risk of developing asthma and kidney diseases.
[0010] Nowadays there are different medications and remedies for the treatment of overweight and obesity, however, to date, there remains a need for drugs that enable weight loss in a short time and without side effects that may put at risk the patient's health.
[0011] Initially, the main therapy to be considered is the improvement in the patient's habits, i.e., increasing exercise and having a proper diet. However, when the obesity problem is not solved through this way it requires drug treatment. Most drugs for the treatment of obesity act by decreasing food intake through an appetite suppression mechanism. Such drugs act at the central nervous system (CNS) level and have an anorexigenic effect. For this reason its use is not recommended for long-term treatments.
[0012] According to the international consensus, the use of obesity drugs is justified when the diet treatment fails, exercise and behavioral management in patients with BMI>30 Kg/m 2 (obese) or BMI>25 Kg/m 2 (overweight) and co-morbidity of medical relevance (type 2 diabetes, hypertension, dyslipidemia, arthropathy, and so on).
[0013] According to the field of invention, the ideal characteristics of a drug product for the treatment of obesity are:
[0014] 1. Demonstrated reduction in weight and associated diseases.
[0015] 2. Tolerable or transient side effects.
[0016] 3. No major adverse reactions after years of use.
[0017] 4. Long-term sustained efficacy.
[0018] 5. Without addictive properties.
[0019] 6. Known mechanism(s) of action.
[0020] 7. Affordability.
[0021] The drugs used for the treatment of obesity are classified according to their mechanism of action as described below:
Appetite inhibitors or satiety stimulators. Adrenergic agents: Diethylpropion, Mazindol, Phentermine, Ephedrine. Selective inhibitors for serotonin uptake: Fluoxetine, Sertraline. Dual action (adrenergic-serotoninergic): Sibutramine. Endocannabinoid receptor 1 inhibitors: Rimonabant. Thermogenics-lipolytics: Ephedrine/Caffeine. Fat absorption inhibitor or lipase enzyme inhibitor: Orlistat. Natural products: Resveratrol.
[0030] Active agent orlistat belongs to the group of inhibitors of the lipase enzyme. This compound is an off-white waxy solid, easily soluble in chloroform, insoluble in water, with a melting point between 40° C.-48° C.
[0031] Orlistat reduces the absorption of fat by the inhibition of pancreatic lipase activity, avoiding the splitting of fats in their simplest components, provoking their disposal without being absorbed. This compound exerts its therapeutic activity in the lumen of the stomach and in the small intestine, forming a covalent bond with the serine in the active site of the gastric and pancreatic lipases.
[0032] Orlistat is administered orally at doses not greater than 360 mg per day, given that higher doses do not have a therapeutic effect. Depending on the patient, different doses may be administered which can be from 30 mg, 60 mg, 120 mg to 240 mg. Different medical publications mention that the usual dose is the administration of 120 mg three times per day.
[0033] In obese patients with type 2 diabetes, orlistat is used in weight reduction, and thus it helps to achieve a better glycemic control and reduces postprandial increments of triglycerides, cholesterol and free fatty acids. Orlistat provides additional control when being administered in combination with antidiabetic agents such as metformin, sulfonylureas and/or insulin.
[0034] In volunteers with normal weight and obese subjects, the systemic exposure to orlistat is minimal. Plasma concentrations of intact orlistat were virtually undetectable (<5 ng/ml) after single administration of 360 mg. In general, plasma concentrations are extremely low (<10 ng/ml or 0.02 μM) with no evidence of accumulation. Studies in people with normal weight or obese have shown that fecal excretion of the unabsorbed drug was the major route of elimination.
[0035] Approximately 97% of the administered dose was excreted in feces and 83% of that was unchanged orlistat.
[0036] Orlistat adverse reactions are, largely, of gastrointestinal nature and are related to the pharmacological effect of the drug in the 30% decrease of the absorption of ingested fat. The commonly observed events are grease stains, flatulence and secretions, fecal urgency, grease/oily stools, oily evacuation, increased defecation and fecal incontinence. A higher incidence of these effects has been observed with an increase of fat content in the diet.
[0037] Similarly it has been determined a decrease in the absorption of vitamin D, E and β-carotene when they are co-administered with orlistat, but serum levels of these vitamins remained within normal limits.
[0038] Resveratrol (3,5,4′-trihydroxystilbene) is a phytoalexin present in grapes and derived products such as wine, and other foods like oysters, peanuts and nuts. It is a powerful antioxidant, polyphenolic, with a molecular formula C 14 H 12 O 3 and molecular weight of 228.25. Is a yellowish white powder, non-hygroscopic, insoluble in water, soluble in alcohol and methanol, insoluble in hydrochloric acid 10% and photosensitive. It naturally exists in the form of cis- and trans-isomer, the most common being the trans-resveratrol found in the skin of grapes.
[0039] The mechanism of action of this active agent is not yet defined, although some publications mention that it is capable of stimulating the SIRT1 gene family, which codifies sirtuins (NAD-dependent histone deacetylases), triggering metabolic processes related to the duration of life, which are the same that are triggered with restricted diets, thus mimicking caloric restriction. Thus, it is assumed that a low calorie and low carbohydrate diet can extend life. Resveratrol is capable of inhibiting several inflammatory enzymes including cyclooxygenase and lipoxygenase.
[0040] In metabolic regulation, resveratrol allows maintaining the effects of a low calorie diet, without changing the food intake, which may be beneficial in the treatment of obesity.
[0041] In animal studies, resveratrol exhibits anti-aging effects, cardioprotective effects (in vitro resveratrol inhibits platelet aggregation), neuroprotective effects (by activating SIRT1 it reduces neurodegenerative diseases), anti-inflammatory and chemopreventive effects and as a metabolic regulator it maintains a low calorie diet, without changing the food intake, which may be beneficial in the treatment of obesity.
[0042] In humans, although the trans-resveratrol appears to be well absorbed when taken orally, its bioavailability is relatively low due to its rapid metabolism and renal elimination (half-life of approximately 8 h) getting very low levels, both intracellular and in plasma. This active agent is removed in its conjugated forms glucoronate and sulfonate. Studies have shown a polymorphism in the intestinal absorption and in the hepatic metabolism, depending on the species used in the studies.
[0043] Various publications have shown that mono-therapy in the treatment of obesity is not effective, combination therapy being indispensable. Nowadays, the literature mentions different combinations for the treatment of obesity and related health problems, however none of them foresees the use of orlistat-resveratrol or provides data on the advantages of this combination or its dosage, clinical trials aren't mentioned either and on the contrary, they warn of adverse effects that may occur.
[0044] For example, international patent application WO 2004/080450 describes the use of orlistat with fibrates however, this combination may cause gastrointestinal and skin problems like puritus, rash or photosensitivity.
[0045] Patent application WO 2001/000205 describes the combination of sibutramine and orlistat. This combination can represent a risk to patients because sibutramine has been withdrawn from the market by health authorities due to adverse cardiovascular effects it causes.
[0046] Mexican patent application No. MX/a/2007/006092 describes the use of orlistat with simvastatin or atorvastatin to decrease the levels of lipids or fatty acids. Combinations herein may develop rhabdomyolysis.
[0047] Mexican patent application No. PA/a/2005/013654 shows the combination of orlistat and bupropion. This combination has the disadvantage that the use of bupropion can cause convulsive episodes and adverse effects on the central nervous system of the patient.
[0048] The combination of the present application avoids the problems of the combinations mentioned in the prior art. The use of orlistat together with resveratrol has the following advantages:
Anti-obesity effect. Induced weight loss. The use of the combination does not require a low caloric intake. Induced weight loss in shorter treatment times. It has tolerable side effects or may even have no side effects. Induction of a better control of blood pressure. Stimulation of improved glycemic profile. Induction of a better control of cholesterol and lipid levels. The combination provides anti-aging and antioxidant effects. The combination has cardioprotective effect. The elimination process of each agent is not affected. The half life of each agent is not affected. The doses of orlistat or resveratrol used in the combination may be lower than those used in the usual way. The combination doesn't cause dependence. The combination modifies positively the desire of food intake.
SUMMARY OF THE INVENTION
[0064] The present invention is directed to a combination and a pharmaceutical composition comprising effective amounts of orlistat, or pharmaceutically acceptable salts thereof, and resveratrol or pharmaceutically acceptable salts thereof.
[0065] The present invention also relates to the combination of orlistat, or pharmaceutically acceptable salts thereof, and resveratrol or its pharmaceutically acceptable salts, for the preparation of a medicament for the treatment of diseases of overweight, obesity and related health problems.
[0066] Similarly, the invention relates to the process for preparing a pharmaceutical composition comprising orlistat and resveratrol.
BRIEF DESCRIPTION OF THE DRAWINGS
[0067] FIG. 1 is a graph showing the status of obesity induced by a high calorie diet in Wistar rats after 3 weeks. The difference in weight between rats with standard diet (negative control group=NCG) and rats with high calorie diet (positive control=PCG) was 35.8.
[0068] FIG. 2 corresponds to a graph of weight gain in the experimental groups. Results of the groups: standard diet (NCG), high calorie diet (PCG), high calorie diet administered with orlistat (OHG), high calorie diet administered with resveratrol (RHG), high calorie diet and the administration of the combination of orlistat-resveratrol in two different concentrations (GH combination 1 and GH combination 2).
[0069] FIG. 3 is a graph on daily food intake during the study period. Animals treated with standard diet maintain a consistent pattern of food consumption (between 13-15 g) and animals fed with the high calorie diet show a plateau in the consumption of less than 16 g/day.
[0070] FIGS. 4A to 4 c are graphs of monitored blood pressure during the study period. FIG. 4A shows the result of diastolic pressure, FIG. 4B shows the course of systolic pressure and FIG. 4C shows the average pressure. These results correspond to all the rats of the experimental groups throughout the 3 weeks. Those animals fed with a high caloric diet showed elevation of the blood pressure levels of up to 25 mmHg, which is assumed as hypertension, a condition which was reversed in week 3 after the treatment with the combination of orlistat-resveratrol.
[0071] FIG. 5 is a graph of serum glucose monitoring. It is seen that during the period of 3 weeks, all groups except the one treated with higher doses of the combination of orlistat-resveratrol, showed a considerable increase in serum levels of postprandial glucose.
[0072] FIG. 6 is a tracking graph of serum liver transaminase. The result shows that the high caloric diet did not alter the activity of any transaminases.
DESCRIPTION OF THE INVENTION
[0073] According to the present invention, there is provided a combination comprising orlistat and resveratrol. The inventors of the present invention have found that the co-administration of these 2 drugs has a synergistic effect in the treatment of diseases like overweight, obesity and related health problems, such as metabolic syndrome, cardiovascular disease, etc.
[0074] The inventors of the present invention found that the combination of orlistat with resveratrol has a pharmacological effect in rats with experimental obesity, being a synergistic effect in weight loss. During the study, the results show that the combination of orlistat and resveratrol is effective in weight reduction in comparison to the separate administration of these active agents.
[0075] To demonstrate the aforementioned, a prospective longitudinal preclinical study in female rats was performed randomly. Once the obesity status was reached (difference between positive and negative control higher than 30%) (see FIG. 1 ), the animals received for 3 weeks oral treatment as follows:
[0076] Group 1. Negative control. Standard diet AD libitum and vehicle (saline solution 1 ml/kg) 3 times per day.
[0077] Group 2. Positive control. High calorie diet AD libitum and vehicle (saline solution 1 ml/kg) 3 times per day.
[0078] Group 3. High calorie diet+orlistat 1.7 mg/kg 3 times per day.
[0079] Group 4. High calorie diet+resveratrol 10 mg/kg 3 times per day.
[0080] Group 5. High calorie diet+orlistat-resveratrol 1.0 mg/5.0 mg/kg 3 times per day.
[0081] Group 6. High calorie diet orlistat-resveratrol 1.7 mg/10.0 mg/kg 3 times per day.
[0082] The used doses of orlistat and resveratrol were based on extrapolation of the clinical use of the drug, individually, in humans, meaning that the dose of orlistat (1.7 mg/kg) is equivalent to 120 mg consumed clinically for weight control, and for resveratrol a dose of 10 mg/kg was used. The prior is not limitative to the use of other doses ranging from 30 mg to 360 mg for orlistat and from 100 mg to 2000 mg for resveratrol, preferably 1000 mg.
[0083] To receive the treatments, the experimental animals were divided into groups of 2 animals and placed on cages to allow them free access to food and water. Every day at the same time (morning, afternoon and evening), the record of consumption (for both: food and water) was made, and the replacement of initial amount, already established (150 g of food and 250 ml of water), was also carried out. On preset days, the measurement of blood pressure by non-invasive methods was performed too.
[0084] The primary endpoint for measuring treatment efficacy was the weight reduction after 3 weeks, although we evaluated the time course of weight gain during this period, as well as the ability of each treatment to reduce excessive weight gain (“obesity”).
[0085] Rats in all groups were evaluated for spontaneous adverse effects such as reflex reduction, well-walking assessment, corneal reflex before and after drug treatments. Additionally, serum values were determined for oxalacetic and piruvic transminases at the end of the study to evaluate possible hepatic problems.
[0086] For the study, Wistar rats received a diet rich in fats and carbohydrates to resemble pathological states of the Zjucker rat, like overweight at an early age (3-5 weeks), hyperlipidemia, hypercholesterolemia, hyperinsulinemia, and development of adipocyte hypertrophy and adipocyte hyperplasia. Wistar rats were given a rich diet in fat and carbohydrates for 3 weeks and the rat is considered to be in an obese state when the difference between the negative and positive control is 30% (see FIG. 1 ).
[0087] During the study, the results show that the orlistat-resveratrol combination is effective for weight reduction in comparison with separate administration of orlistat and resveratrol (see FIG. 2 ).
[0088] The combination of the present invention as shown in the study, exhibited a positive effect in the reduction of food intake. FIG. 3 shows that while the animals treated with the standard diet maintained a consistent pattern of food intake (13 to 15 mg), animals fed with the high-calorie diet and treated with orlistat-resveratrol showed a plateau in the consumption, that is, they began consuming more than 16 g/day, and as time passed, the intake decreased to 13 to 14 g. This phenomenon could be explained as an attempt to adapt to food from a voracious consumer start due to the palatability of the food.
[0089] The follow up was made on the physiological and biochemical cardiovascular indicators (blood pressure, lipid levels and cholesterol) as a way to find the pathophysiological consequences of consumption of a high calorie diet, as well as potential therapeutic effects of the study treatments.
[0090] FIGS. 4A to 4C show the time course of systolic, diastolic and mean blood pressure of the rats of all the experimental groups throughout 3 weeks of follow-up. As anticipated, those animals fed with a high calorie diet showed an elevation of the blood pressure levels up to 25 mmHg at week 2, this is, it could be proposed that animals under this condition are under a phase of “hypertension”, however this state is reversed after the third week, apparently influenced by weight loss due to the treatment. It is important to observe that the bigger decrease in blood pressure is given by the orlistat-resveratrol combination, however there is an increased effect for the treatment orlistat-resveratrol 1.7/10 mg/kg body weight in the pressure decrease.
[0091] Regarding serum glucose levels, during the evaluation period it is observed that the administered treatments increased postprandial glucose levels, although to a lesser extent than the orlistat-resveratrol combination; apparently the administration of the treatments causes a more efficient management of the available energy, due to the high calorie diet (see FIG. 5 ).
[0092] Similarly, the increase of liver transaminases was monitored as indicators of any potential hepatic adverse effect of the treatments. FIG. 6 shows an increase of the transaminase levels using the treatments, compared with the high calorie diet. For the orlistat-resveratrol combination the increase was lower and no animal damages were observed, therefore an enhanced safety of the use of the combination orlistat-resveratol is observed.
[0093] The combination of orlistat-resveratrol, or pharmaceutically acceptable salts thereof, is administered in different formulations, a preferred one being the orally-administered formulation for its comfort. It can be presented as a suspension, capsule, tablet, granule, powder, etc.
[0094] Now, it is not obvious to combine 2 active ingredients when, due to their physicochemical properties, it is complicated to manufacture a physicochemically stable formulation that meets the required characteristics for administration. In the case of orlistat, its waxy consistency complicates its formulation process when combined with another active ingredient. This is the main reason why it is not possible to find publications that refer to the combination of orlistat-resveratrol.
[0095] The present invention provides a stable pharmaceutical composition which, surprisingly, solves formulation problems due to physical and chemical characteristics of orlistat and resveratrol. It should not be forgotten than orlistat melts at approximately 43° C. (40°-44° C.), said temperature is reached during the manufacturing processes, thus complicating significantly the obtention of a stable formulation that meets the requirements for human use and having an acceptable appearance.
[0096] The inability to maintain in one single dosage unit both active ingredients was observed due to their different physicochemical properties of orlistat (waxy) and resveratrol (powder), however, the present invention employs a heat-resistant system which allows the coexistence of the active ingredients.
[0097] As already mentioned, the low melting point of orlistat complicated considerably the manufacture of an oral dosage form, because during the manufacturing process temperatures above 40° C. were reached, provoking the fusion of the active ingredient orlistat.
[0098] The process of the present invention comprises: forming a mixture of orlistat with pharmaceutically acceptable excipients which can be, as non-limitative examples, cellulose derivatives, microcrystalline cellulose, lactose or corn starch; heating the mixture at a temperature of 50 to 70° C.; extruding the mixture and forming spheres or beads comprising orlistat; cooling down the powders; and finally coating the powder blend with a dispersion of resveratrol and a polymer selected from hydroxypropyl methylcellulose, polyvinylpyrrolidone, hydroxypropyl cellulose or cellulose derivatives. This last step of coating the powders can be performed in a fluidized bed equipment or similar.
[0099] The combination of the invention can be used for preparing a drug product for the treatment of diseases like overweight, obesity and related health problems. The amount of orlistat used can be between 30 mg to 360 mg, preferably 120 mg. The amount of resveratrol used can vary from 100 mg to 2000 mg, preferably 1000 mg. Orlistat and resveratrol can be together in the same dosage form or may present in different pharmaceutical dosage forms or different dosage units.
[0100] The invention has been sufficiently described so that a person of ordinary skill in the art could reproduce and obtain the results mentioned in this document. However, any person skilled in the art to which this invention belongs may be able to make modifications not described in this application. Therefore, if the application of these modifications in a given composition requires the matter claimed in the following clauses, such compositions must fall within the scope of the present invention.
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The present invention relates to the pharmaceutical field, especially the field of combination and pharmaceutical compositions that comprise a lipase inhibitor and a phytoalexin and pharmaceutically acceptable vehicles or excipients; the present invention also relates to the method for manufacturing compositions containing the combination and the use of said composition in the treatment of conditions of excess weight, obesity and related health problems.
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TECHNICAL FIELD
[0001] This disclosure relates to a minidisk for a gas turbine engine turbine section, and more particularly, the disclosure relates to a feature on the minidisk for assembly and disassembly of the turbine section.
BACKGROUND OF THE INVENTION
[0002] Gas turbine engines typically include a compressor section, a combustor section and a turbine section. During operation, air is pressurized in the compressor section and is mixed with fuel and burned in the combustor section to generate hot combustion gases. The hot combustion gases are communicated through the turbine section, which extracts energy from the hot combustion gases to power the compressor section and other gas turbine engine loads.
[0003] Early minidisks were used as windage covers disposed upon rotating gas turbine engine rotors. More modern minidisks are also used to cool the turbine rotor. An axial extension of the minidisk may extend into an area having a seal assembly and bearing.
[0004] A typical turbine section includes multiple turbine rotors that are secured to one another using a very large press fit. The minidisk has used an annular recess on the axial extension. A tool cooperates with the annular recess to apply a press load to assemble or disassemble the turbine rotors for service. One prior art arrangement required the entire bearing and seal assembly to be removed to gain access to the annular recess, which made servicing the turbine section considerably more costly.
SUMMARY
[0005] In one exemplary embodiment, an assembly for a gas turbine engine includes a minidisk that includes an axial extension extending from a disc. The axial extension includes an inner diameter surface and a recess arranged radially opposite the inner diameter surface. The recess provides a radially outwardly extending flange and a bumper extending radially inward from and proud of the inner diameter surface.
[0006] In a further embodiment of any of the above, the recess is axially elongated compared to a radial depth of the recess.
[0007] In a further embodiment of any of the above, the recess axially overlaps the bumper.
[0008] In a further embodiment of any of the above, the assembly includes a turbine rotor having a hub. The minidisk is mounted on the hub and the hub is operatively supported relative to an engine static structure by a bearing.
[0009] In a further embodiment of any of the above, the assembly includes a seal assembly arranged between the minidisk and the bearing to create a bearing compartment.
[0010] In a further embodiment of any of the above, the assembly includes a sleeve supported by the hub. The bearing is mounted to the sleeve.
[0011] In a further embodiment of any of the above, the hub includes circumferentially spaced radially outwardly extending first tabs. The axial extension includes circumferentially spaced radially inwardly extending second tabs. The first and second tabs are axially aligned with one another and fingers of the sleeve are received in circumferential gaps provided between the first and second tabs to prevent relative circumferential movement between the first and second tabs.
[0012] In a further embodiment of any of the above, the sleeve includes an outer diameter surface. A clearance is provided between the bumper and the outer diameter surface of 0.000-0.005 inch (0.000-0.127 mm).
[0013] In a further embodiment of any of the above, the seal assembly is secured to the engine static structure. The seal assembly includes a seal support and a carbon seal axially slidable relative to the seal support. The flange extends axially beyond the seal support.
[0014] In a further embodiment of any of the above, the flange provides forward and aft tool engagement faces configured to be accessible by a tool with at least a portion of the seal assembly mounted the engine static structure.
[0015] In a further embodiment of any of the above, the turbine rotor provides a second turbine rotor. A first turbine rotor is secured to the second turbine rotor at a joint by an interference fit. The flange is configured to be manipulated by a tool to alter the interference fit at the joint.
[0016] In another exemplary embodiment, a method of working on a gas turbine engine section includes inserting a tool into a cavity beneath a seal assembly, and engaging a flange of a minidisk with the tool to manipulate first and second rotors with respect to one another.
[0017] In a further embodiment of any of the above, the method includes removing a portion of a bearing prior to performing the inserting step.
[0018] In a further embodiment of any of the above, the method includes removing a seal land prior to the performing the inserting step, with portions of the seal assembly remaining mounted to an engine static structure during the engaging step.
[0019] In a further embodiment of any of the above, the engaging step includes closing the tool radially inward to engage the flange.
[0020] In a further embodiment of any of the above, the method includes the step of separating the first and second rotors at a joint having an interference fit.
[0021] In a further embodiment of any of the above, the method includes the step of joining the first and second rotors at a joint in an interference fit.
[0022] In a further embodiment of any of the above, the engaging step includes deflecting a bumper of the minidisk into engagement with a surface of one of the first and second rotors.
[0023] In a further embodiment of any of the above, the first and second rotors are first and second turbine rotors.
[0024] In a further embodiment of any of the above, the method includes a sleeve locking the minidisk to one of the first and second rotors.
[0025] In a further embodiment of any of the above, the engaging step includes deflecting a bumper of the minidisk into engagement with a surface of an assembly tool.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] The various features and advantages of the disclosed examples will become apparent to those skilled in the art from the following detailed description. The drawings that accompany the detailed description can be briefly described as follows.
[0027] FIG. 1 schematically illustrates a gas turbine engine embodiment.
[0028] FIG. 2 is a schematic cross-sectional view through a turbine section.
[0029] FIG. 3 is a partial cross-sectional view of the turbine section shown in FIG. 2 in more detail.
[0030] FIG. 4 is an enlarged view of a portion of the turbine section during a disassembly procedure.
[0031] FIG. 5 is a cross-sectional perspective view of a minidisk, turbine hub and sleeve shown in FIGS. 3 and 4 .
[0032] FIG. 6 is a cross-sectional view taken along line 6 - 6 in of FIG. 4 .
DETAILED DESCRIPTION
[0033] FIG. 1 schematically illustrates an example gas turbine engine 20 that includes a fan section 22 , a compressor section 24 , a combustor section 26 and a turbine section 28 . Alternative engines might include an augmenter section (not shown) among other systems or features. The fan section 22 drives air along a bypass flow path B while the compressor section 24 draws air in along a core flow path C where air is compressed and communicated to a combustor section 26 . In the combustor section 26 , air is mixed with fuel and ignited to generate a high pressure exhaust gas stream that expands through the turbine section 28 where energy is extracted and utilized to drive the fan section 22 and the compressor section 24 .
[0034] Although the disclosed non-limiting embodiment depicts a turbofan gas turbine engine, it should be understood that the concepts described herein are not limited to use with turbofans as the teachings may be applied to other types of turbine engines and other turbo machinery; for example a turbine engine including a three-spool architecture in which three spools concentrically rotate about a common axis and where a low spool enables a low pressure turbine to drive a fan via a gearbox, an intermediate spool that enables an intermediate pressure turbine to drive a first compressor of the compressor section, and a high spool that enables a high pressure turbine to drive a high pressure compressor of the compressor section.
[0035] The example engine 20 generally includes a low speed spool 30 and a high speed spool 32 mounted for rotation about an engine central longitudinal axis X relative to an engine static structure 36 via several bearing systems 38 . It should be understood that various bearing systems 38 at various locations may alternatively or additionally be provided.
[0036] The low speed spool 30 generally includes an inner shaft 40 that connects a fan 42 and a low pressure (or first) compressor section 44 to a low pressure (or first) turbine section 46 . The inner shaft 40 drives the fan 42 through a speed change device, such as a geared architecture 48 , to drive the fan 42 at a lower speed than the low speed spool 30 . The high-speed spool 32 includes an outer shaft 50 that interconnects a high pressure (or second) compressor section 52 and a high pressure (or second) turbine section 54 . The inner shaft 40 and the outer shaft 50 are concentric and rotate via the bearing systems 38 about the engine central longitudinal axis X.
[0037] A combustor 56 is arranged between the high pressure compressor 52 and the high pressure turbine 54 . In one example, the high pressure turbine 54 includes at least two stages to provide a double stage high pressure turbine 54 . In another example, the high pressure turbine 54 includes only a single stage. As used herein, a “high pressure” compressor or turbine experiences a higher pressure than a corresponding “low pressure” compressor or turbine.
[0038] The example low pressure turbine 46 has a pressure ratio that is greater than about five (5). The pressure ratio of the example low pressure turbine 46 is measured prior to an inlet of the low pressure turbine 46 as related to the pressure measured at the outlet of the low pressure turbine 46 prior to an exhaust nozzle.
[0039] A mid-turbine frame 57 of the engine static structure 36 is arranged generally between the high pressure turbine 54 and the low pressure turbine 46 . The mid-turbine frame 57 further supports bearing systems 38 in the turbine section 28 as well as setting airflow entering the low pressure turbine 46 .
[0040] The core airflow C is compressed by the low pressure compressor 44 then by the high pressure compressor 52 mixed with fuel and ignited in the combustor 56 to produce high speed exhaust gases that are then expanded through the high pressure turbine 54 and low pressure turbine 46 . The mid-turbine frame 57 includes vanes 59 , which are in the core airflow path and function as an inlet guide vane for the low pressure turbine 46 . Utilizing the vane 59 of the mid-turbine frame 57 as the inlet guide vane for low pressure turbine 46 decreases the length of the low pressure turbine 46 without increasing the axial length of the mid-turbine frame 57 . Reducing or eliminating the number of vanes in the low pressure turbine 46 shortens the axial length of the turbine section 28 . Thus, the compactness of the gas turbine engine 20 is increased and a higher power density may be achieved.
[0041] The disclosed gas turbine engine 20 in one example is a high-bypass geared aircraft engine. In a further example, the gas turbine engine 20 includes a bypass ratio greater than about six (6), with an example embodiment being greater than about ten (10). The example geared architecture 48 is an epicyclical gear train, such as a planetary gear system, star gear system or other known gear system, with a gear reduction ratio of greater than about 2.3.
[0042] In one disclosed embodiment, the gas turbine engine 20 includes a bypass ratio greater than about ten (10:1) and the fan diameter is significantly larger than an outer diameter of the low pressure compressor 44 . It should be understood, however, that the above parameters are only exemplary of one embodiment of a gas turbine engine including a geared architecture and that the present disclosure is applicable to other gas turbine engines and other turbo machinery.
[0043] A significant amount of thrust is provided by the bypass flow B due to the high bypass ratio. The fan section 22 of the engine 20 is designed for a particular flight condition—typically cruise at about 0.8 Mach and about 35,000 feet. The flight condition of 0.8 Mach and 35,000 ft., with the engine at its best fuel consumption—also known as “bucket cruise Thrust Specific Fuel Consumption (‘TSFC’)”—is the industry standard parameter of pound-mass (lbm) of fuel per hour being burned divided by pound-force (lbf) of thrust the engine produces at that minimum point.
[0044] “Low fan pressure ratio” is the pressure ratio across the fan blade alone, without a Fan Exit Guide Vane (“FEGV”) system. The low fan pressure ratio as disclosed herein according to one non-limiting embodiment is less than about 1.50. In another non-limiting embodiment the low fan pressure ratio is less than about 1.45.
[0045] “Low corrected fan tip speed” is the actual fan tip speed in ft./sec divided by an industry standard temperature correction of [(Tram ° R)/(518.7° R)] 0.5 . The “Low corrected fan tip speed”, as disclosed herein according to one non-limiting embodiment, is less than about 1150 ft./second.
[0046] Referring to FIG. 2 , a cross-sectional view through the turbine section 28 is illustrated. In the example turbine section 28 , first and second arrays 66 , 68 of circumferentially spaced fixed vanes 70 , 72 are axially spaced apart from one another. A first stage array 74 of circumferentially spaced turbine blades 76 , mounted to a first rotor disk 78 , is arranged axially between the first and second fixed vane arrays 70 , 72 . A second stage array 80 of circumferentially spaced turbine blades 82 , mounted to a second rotor disk 94 , is arranged aft of the second array 68 of fixed vanes 72 .
[0047] The turbine blades 76 , 82 each include a tip 84 , 86 adjacent to a blade outer air seals 88 , 90 of a case structure 92 . The first and second stage arrays 66 , 68 of turbine vanes and first and second stage arrays 74 , 80 of turbine blades are arranged within a flow path F and are operatively connected to the shaft 32 , which is rotatable about an axis X.
[0048] One of ordinary skill in the art will recognize that the teachings of disclosed arrangement may be used for either the high pressure turbine section 54 or the low pressure turbine section 46 . Moreover, one of ordinary skill will recognize that the teachings herein can be used wherever high press fits are used and may include other parts of the engine like the high pressure compressor section 52 , more turbine stages or other types of engines besides the gas turbine engine 20 shown herein.
[0049] Referring to FIG. 3 , the first and second rotor discs 78 , 94 are secure to one another at a joint 96 using a very high press fit load. This press fit load must be overcome during assembly and disassembly procedures of the turbine section 28 , for example, during service.
[0050] A minidisk 100 is mounted to the aft side of the second turbine rotor 94 , which is the last stage in the example turbine section 28 . The minidisk 100 provides a plate 101 that creates a cavity in the turbine section 28 that is cooled to lower turbine rotor temperatures. An axial extension 99 is provided by the minidisk 100 and is supported by hub 98 of the second turbine rotor 94 . The hub 98 operatively supports the bearing 38 to support the turbine section 28 for rotation relative to the engine static structure 36 .
[0051] In the example, a sleeve 102 is provided radially between the hub 98 and an inner race 120 of the bearing 38 . An air seal assembly 106 is provided between the turbine section 28 and the bearing 38 , which is arranged within a bearing compartment that is separated from hot gases by the seal assembly 106 . Heat shields 108 are used to further insulate the bearing compartment and seal assembly 106 from hot gases.
[0052] The example seal assembly 106 includes a seal support 110 mounted to the engine static structure 36 . Multiple circumferentially spaced pins 112 are secured to the seal support 110 . A carrier 114 having a carbon seal 116 is slidably supported by the pins 112 for axial movement. A seal land 118 is mounted to the sleeve 102 and arranged adjacent to the inner race 120 . The seal land 118 engages the carbon seal 116 during rotation of the seal land 118 with the second turbine rotor 94 and hub 98 to seal the bearing compartment from hot gases. A retainer 122 secures the hub 98 , minidisk 100 and sleeve 102 to one another in a stack to maintain assembly loads.
[0053] Referring to FIGS. 4 and 6 , the hub 98 includes circumferentially spaced first tabs 124 that extend radially outward. The axial extension 99 includes circumferentially spaced second tabs 126 that extend radially inward. During assembly, the second tabs 126 are slid through circumferential gaps 128 between the first tabs 124 as the minidisk 100 is mounted onto the hub 98 . The minidisk 100 and second turbine rotor 94 are then rotated relative to one another to position the second tabs 126 in alignment with and behind the first tabs 124 , as shown in FIGS. 4 and 6 . The minidisk 100 is axially retained to the hub 98 in this assembled position. Fingers 130 of the sleeve 102 are inserted into the circumferential gaps 128 to maintain the circumferential position of the first and second tabs 124 , 126 and lock the minidisk 100 to the second turbine rotor 94 .
[0054] An outer diameter surface 132 of the sleeve 102 supports the axial extension 99 during disassembly of the turbine section 28 . A radius 134 adjoins the second tabs 126 and an inner diameter surface 136 of the axial extension 99 . A bumper 142 extends radially inward from and proud of the inner diameter surface 136 , which is cylindrical in shape in the example. In one example, a clearance between the outer diameter surface 132 and the bumper 142 is about 0.005 inch (0.127 mm).
[0055] Referring to FIGS. 4 and 5 , recess 138 is provided in the axial extension 99 on a surface radially opposite the inner diameter surface 136 to provide a flange 140 . The recess is elongated to reduce the size and weight of the axial extension 99 . However, this increases the flexibility of the axial extension during assembly and disassembly procedures. In the example, the recess 138 begins in an area that axially overlaps the second tabs 126 . Portions of the flange 140 and bumper 142 axially overlap one another. In the example, the axial length of the recess 138 is at least four times that of the radial depth of the recess 138 . The flange 140 is axially outboard of portions of the seal assembly 106 , such as the heat shield 108 and seal support 110 , such that the flange 140 is readily accessible.
[0056] During assembly or disassembly, such as during a service procedure, the inner bearing race 120 and seal land 118 are removed exposing a cavity 146 , as shown in FIG. 4 . The remaining portions of the bearing 38 and seal assembly 106 , including the carrier 114 and carbon seal 116 , can remain mounted to the engine static structure 36 . A tool 148 , similar to a collet arrangement, is inserted into the cavity 146 at position P 1 . Lips 150 of the tool 148 are deflected radially inward to position P 2 to engage the flange 140 . During assembly, the lips 150 engage an aft face 154 to apply a pushing load on the minidisk 100 through the flange 140 . During disassembly, the lips engage a forward face 152 to apply a pulling load on the flange 140 , which can be used to separate the first and second turbine rotors 78 , 94 at the joint 96 .
[0057] During assembly and disassembly procedures, in particular during disassembly, the axial extension 99 is deflected radially inward such that the bumper 142 contacts the outer diameter surface 132 . The bumper 142 and its tight clearance with respect to the outer diameter surface 132 prevents the axial extension from plastically deforming or breaking, which enables a smaller, lighter axial extension to be used. In this example, surface 132 is part of sleeve 102 but in another embodiment can be part of tool 148 (shown in the same position as the sleeve in FIG. 4 ).
[0058] The preceding description is exemplary rather than limiting in nature. Variations and modifications to the disclosed examples may become apparent to those skilled in the art that do not necessarily depart from the essence of this disclosure. The scope of legal protection given to this disclosure can only be determined by studying the following claims.
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An assembly for a gas turbine engine includes a minidisk that includes an axial extension extending from a disc. The axial extension includes an inner diameter surface and a recess arranged radially opposite the inner diameter surface. The recess provides a radially outwardly extending flange and a bumper extending radially inward from and proud of the inner diameter surface. A method of working on a gas turbine engine section includes inserting a tool into a cavity beneath a seal assembly, and engaging a flange of a minidisk with the tool to manipulate first and second rotors with respect to one another.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a camera of the type in which a flash device is used, and more particularly, to a built-in flash camera or a camera with an external flash device of the type in which the flash device is automatically flashed when it is determined on the basis of the output of a photometry circuit of the camera that flashing of the flash device ensures a correct exposure, as with a dark or back lighted scene, and in which flashing of the flash device is prohibited when it is determined that flashing of the flash device is not necessary, as with an outdoor scene in the daytime.
2. Description of the Related Art
Various types of built-in flash cameras or cameras with an external flash device of the type in which the flash device is automatically flashed when it is determined at a photometry stage that the scene is dark or back lighted have been proposed recently.
In such cameras, charging of the flash device may be started after it has been determined that the scene is dark or back lighted. In that case, operation of a shutter release button has to be delayed until the charging of the flash device is completed, making it impossible for a photographer to take a picture immediately. In order to eliminate this shortcoming, a camera of the type in which waiting for the charging of the flash device is eliminated by automatically starting charging of the flash device for the next picture immediately after a picture has been taken has been proposed.
In the conventional camera of the above-described type, the flash is continuously charged until the voltage of the flash reaches a predetermined value required for flashing in a state where no monitoring is performed, charging being stopped when the voltage has reached the predetermined value. In consequence, in a case where a battery has been used up and the voltage of the battery is too low to charge the flash, charging of the flash may not be completed for a long period of time, during which time the booster circuit for the flash is continuously operated, causing heating of the component of the booster circuit, such as a transistor or a coil.
In that case, if use of the battery is stopped for a while, the voltage may recover by virtue of the characteristics of the battery, making it possible for the flash to be charged by that battery. However, in a case where the battery is used for a long period of time, it is often used up to such a degree that recovery thereof is impossible.
Furthermore, in the above-described type of camera, when the flash has been charged to a voltage sufficient for flashing, charging is stopped instantly.
However, after charging, the capacitor for the flash leaks gradually, thereby gradually reducing the charged voltage.
In consequence, the voltage may drop to a value too low for flashing by the time the next picture is taken. In that case, supplementary charging has to be performed immediately before the picture is taken, and operation of the shutter release button has to be meanwhile delayed.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a camera or a flash device which is capable of eliminating the aforementioned problems of the prior art.
To this end, the present invention provides in one aspect a flash device for use in the conventional camera. This flash device has the function of stopping the charging of the flash device when the flash device fails to acquire the voltage required for flashing within a fixed period of time.
Another object of the present invention is to provide a camera of the type in which a flash device is used and which enables the supplementary charging of the flash device to be eliminated, thereby making series photography possible.
To this end, the present invention provides in one aspect a camera of the type in which the flash device is charged immediately after a picture has been taken until its voltage reaches the minimum value required for flashing for the next photographic operation and in which charging of the flash device is stopped when the flash device has been further charged for a fixed period of time after the voltage of the flash device reaches the minimum necessary voltage.
The present invention provides in one aspect a camera or a flash device which comprises first output means for outputting a signal indicating that charging of the flash device is permitted, and first control means for switching over charging and stoppage of charging of the flash device in response to the signal from the first output means. In this camera, in a case where the flash device is flashed, even if it is determined that the flash device has been charged to a voltage higher than that which ensures a correct exposure, the flash device is further charged for a fixed period of time and then the camera is used for a subsequent photographic operation.
Other objects of the present invention will become more apparent from the following description of the preferred embodiment thereof, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a circuit diagram of an electric circuit for a camera, showing an embodiment of the present invention; and
FIGS. 2(A) and 2(B) are flowcharts of the programs, explaining the operation of the circuit of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a circuit diagram of an electric circuit for a built-in flash single-lens reflex camera, showing an embodiment of the present invention.
In FIG. 1, a reference numeral 1 denotes a DC-to-DC converter for boosting the output of a battery VBAT which is the power source of a flash device; 2 denotes a microcomputer for controlling the operation of the circuit; 3 denotes an analog-to-digital converting circuit; and 4 denotes a light metering element which may be a silicon photo-diode or the like. The light metering element 4 is composed of a plurality of metering elements so as to achieve the metering of light on the divided areas of a picture frame. The output of the light metering element 4 is converted into a digital signal by the A/D converting circuit 3, and the converted signal is transmitted to the microcomputer 2 through a bus line BUS.
A reference symbol SW denotes a switch which turns on in association with the pressing of a release button of the camera; R1 denotes a pull-up resistor; MG1 denotes an electromagnet which is energized when a mechanism member (not shown) for locking the running of a leading curtain of a shutter is to be disengaged; MG2 denotes an electromagnet which is energized when a mechanism member (not shown) for locking the running of a trailing curtain of the shutter is to be disengaged; TR1 denotes a switching transistor for switching on the electromagnet MG1; TR2 denotes a switching transistor for switching on the electromagnet MG2. The bases of the transistors TR1 and TR2 are respectively connected to output ports P4 and P5 of the microcomputer 2 through base resistors R5 and R6.
The output of the converter 1 is connected to a flash device flashing circuit. A trigger capacitor TC for starting the flashing is grounded at one end. The other end of the trigger capacitor TC is connected to the output of the converter 1 through a resistor R2 and to a thyristor SI through a coil C1. A gate of the thyristor SI is connected to an output port P1 of the microcomputer 2, so that flashing of the flash device can be controlled by the microcomputer 2.
A reference symbol MC denotes a main capacitor; XE denotes a xenon flashtube; R3 and R4 denote voltage dividing resistors used to detect the voltage charged to the main capacitor MC. The divided voltages of the main capacitor MC are input to an input port P2 of the microcomputer 2 so as to inform the microcomputer 2 whether or not the main capacitor MC is sufficiently charged. A reference symbol TR3 denotes a switching transistor which switches on and off the supply of power to the flash device flashing circuit including the converter 1. A base of the switching transistor TR3 is connected to an output port P0 of the microcomputer 2 through a base resistor R7, by means of which the microcomputer 2 controls the supply of power to the flash device.
Next, the operation of the electric circuit arranged in the manner shown in FIG. 1 will be described below with reference to the flowchart of the operation of the microcomputer 2.
FIGS. 2(A) and 2(B) are flowcharts of one of the operations of the microcomputer 2.
Step S1
It is determined whether or not the release button switch SW is on.
If the release button switch SW is on, the processing goes to step S2. If the switch SW is off, the processing returns to step S1 and repeats the processing of step S1 until the release button is pressed.
Step S2
The microcomputer 2 outputs a logical high level signal from the output port P0 to turn off the switching transistor TR3 and thereby stop supply of power to the flash device circuit.
Step S3
The output of the light metering element 4 is supplied to the A/D converting circuit 3 to obtain light metering data. Determination as to whether or not it is a dark or back lighted scene which requires flashing of the flash device is made on the basis of this metering data. In this determination, the output of the light metering element 4 may be compared with a reference value, and it may be determined that flashing of the flash device is necessary if the output of the light metering element 4 is, for example, smaller than the reference value.
Step S4
If it is determined in step S3 that flashing is not necessary, the processing goes to step S19. If the flashing is necessary because of a back light or dark scene, the processing goes to step S5.
Step S5
The microcomputer 2 outputs a logical low level signal from the output port P0 to turn on the switching transistor TR3 and thereby start supply of power to the flash device flashing circuit.
Step S6
"1" is set in a register A which memorizes that the flash device has been flashed and which determines whether or not the flash-device is charged.
Step S7
A timer which is designed to count 10 seconds is started. A time interval of 10 seconds is the upper limit of the charging time of the flash device.
Step S8
The microcomputer 2 determines by reading the input port P2 whether or not the charging of the flash device has been completed. The voltage dividing resistors R3 and R4 are set such that they produce a voltage which exceeds the input threshold of the microcomputer 2 when the capacitor has been charged to a sufficient voltage. A logical high level signal is therefore input to the input port P2 when the charging has been completed, and then the processing goes to step S11. If the charging is not completed, the processing goes to step S9.
Step S9
It is determined whether or not 10 seconds set in the timer is up. If the time set in the timer is up, it is determined that charging of the flash device has not been completed within a predetermined period of time, and the processing goes to step S10. If the time is not yet up, the processing returns to step S8 and execution of the processing returns to step S8 and execution of the processings S8 and S9 is repeated. Once the charging of the flash device has been completed, the processing goes from step S8 to step S11.
Step S10
Since the charging was not completed within the predetermined period of time, the switching transistor TR3 is turned off to stop supply of power to the flash device, thereby completing the sequence.
Step S11
After the charging of the flash device has been completed, the flash device is charged for another 1 second. In this way, the charging voltage can be raised to a level which ensures flashing of the flash device even when the charging voltage gradually drops due to the leakage which occurs during the mirror-up operation and the driving of a diaphragm.
Step S12
Since the mirror-up and the driving of the diaphragm consume a large amount of power, the switching transistor TR3 is turned off and the charging of the flash device is thereby stopped.
Step S13
The mirror is sprung up by energizing a motor (not shown).
Step S14
The diaphragm (not shown) of a lens is narrowed to a position determined by the metered light value.
Step S15
The microcomputer 2 outputs a logical high level signal from the output port P4 to turn on the switching transistor TR1 and thereby energize the electromagnet MG1. This causes the leading curtain of a shutter (not shown) to run, thereby causing an exposure to be started.
Step S16
The microcomputer 2 outputs a logical high level signal from the output port P1 to turn on the thyristor SI and thereby discharge the trigger capacitor TC through the coil C1. This causes the coil C1 to apply a high voltage to the outer periphery of the xenon flashtube XE, thereby causing the xenon flashtube Xe to flash.
Step S17
Completion of the exposure is awaited to obtain a correct exposure determined by the metered light value.
Step S18
The microcomputer 2 outputs a logical high level signal from the output port P5 to turn on the switching transistor TR2 and thereby energize the electromagnet MG2. This causes the trailing curtain (not shown) of the shutter to run, thereby completing the exposure.
If it is determined in step S4 that flashing is not necessary, the following processings are carried out.
Step S19
"0" is set in the register A which memorizes that the flash device has been flashed and which determines whether or not the flash device is charged. "0" means that flashing of the flash device is not performed.
Thereafter, the same processings as those carried out when the flashing is to be performed are executed. More specifically, step S20 which is similar to step S13, step S21 similar to step S14, step S22 similar to step S15, step S23 similar to step S17 and step S24 similar to step S18 are executed in that order.
The processings from step S20 to step S24 represent series of exposure operations. Since the thyristor SI is not turned on, flashing is not performed regardless of completion or non-completion of the charging of the flash device.
Step S25
A film transporting and shutter charging motor (not shown) is energized to transport a film and to charge the shutter.
Step S26
It is determined whether or not the release button is still being pressed.
Pressing of the release button means that series of pictures are being taken. In consequence, the processing returns to step S2. If the release button is not pressed, the processing goes to step S27, and as to whether or not charging of the flash device is performed for a subsequent photographic operation is determined.
Step S27
Whether the flash device has been flashed or not, the register A is checked after the exposure operation has been completed. If it is determined that "0" is set in the register A, the processing returns to step S1 without charging the flash device and subsequent pressing of the release button is awaited. If "0" is not set in the register A, the processing goes to step S28.
Step S28
When "0" is not set in the register A, the microcomputer 2 outputs a logical low level signal from the output port P0 to turn on the switching transistor TR3 and thereby starts supply of power to the flash device flashing circuit to prepare the camera for a subsequent photographic operation.
Step S29
The time which is designed to count 10 seconds is started. A time interval of 10 seconds is the upper limit of the charging time of the flash device.
Step S30
The microcomputer 2 determines by reading the input port P2 whether or not the charging of the flash device has been completed. The voltage dividing resistors R3 and R4 are set such that they produce a voltage which exceeds the input threshold of the microcomputer 2 when the capacitor has been charged to a sufficient voltage. A logical high level signal is therefore input to the input port P2 when the charging has been completed, and then the processing goes to step S33. If the charging is not completed, the processing goes to step S31.
Step S31
It is determined whether or not 10 seconds set in the timer is up. If the time set in the timer is up, it is determined that charging of the flash device has not been completed within a predetermined period of time, and the processing goes to step S32. If the time is not yet up, the processing returns to step S30 and execution of the processings S30 and S31 is repeated. Once the charging of the flash device has been completed, the processing goes from step S30 to step S31.
Step S32
Since the charging was not completed within the predetermined period of time, the switching transistor TR3 is turned off to stop supplying power to the flash device, thereby completing the sequence.
Step S33
After the charging of the flash device has been completed, the flash device is charged for another 2 seconds. In this way, the charging voltage can be maintained at a level which ensures that a picture can be taken with flashing of the flash device without release time lag even when the charging voltage is gradually decreased due to the leakage which occurs before a subsequent picture is taken.
Step S34
The switching transistor TR3 is turned off and charging of the flash device is stopped. Thereafter, the processing returns to the step S1 to prepare the camera for a subsequent pressing operation of the release button.
As will be understood from the foregoing description, when the flash device cannot be charged within a predetermined period of time after a picture has been taken, charging of the flash device is stopped, thus eliminating any disadvantage that occurs when charging of the flash device continues for a long time after a picture has been taken.
Furthermore, since the flash device is further charged for a predetermined period of time after it has been charged to a predetermined voltage, even if leakage occurs afterwards, the flash device can be maintained in a state in which it can flash.
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Disclosed is a camera with a flash device, in particular, a camera with a flash device of the type in which charging of the flash device is suspended when a charged state of the flash device reaches a predetermined level. The above-described type of camera is characterized in that the charging of the flash device is not suspended immediately after the charged state of the flash device has reached the predetermined level but that it is suspended after the flash device has been further charged for a predetermined period of time.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a national stage application under 35 U.S.C. §371 of International Application No. PCT/EP2011/072243, filed Dec. 8, 2011, which in turn claims priority to United Kingdom Patent Application No. 1020811.4, filed Dec. 8, 2010, the contents of each of which are incorporated herein by reference in their entireties.
FIELD OF THE INVENTION
The present invention relates to a compound comprising a tetracycline, and an associated molecule that is capable of releasing nitric oxide (NO). Also disclosed are methods for the preparation of such compounds, and their use in treating or preventing heart failure, optionally heart failure caused by or associated with diastolic dysfunction.
BACKGROUND TO THE INVENTION
The prevalence of heart failure (HF) is increasing in the developed world and the cost of providing medical care for an expanding HF population imposes an increasingly heavy burden on healthcare systems throughout the world. Most commonly, HF is associated with impaired left ventricular (LV) systolic function. However, at least half of all patients with typical symptoms of congestive HF have a normal or slightly reduced left ventricular ejection fraction (LVEF) (>50%). The predominant cause of heart failure with preserved ejection fraction (HFpEF) is diastolic heart failure (DHF). Heart failure (HF) with preserved ejection fraction (HFpEF) is predominantly caused by hypertension, is often preceded by asymptomatic left ventricular diastolic dysfunction (ALVDD) and has few defined therapies. The predominant aetiological cause of DHF is myocardial fibrosis as a result of long standing hypertension and metabolic abnormalities associated with diabetes and obesity. The rising prevalence of metabolic disease due to the obesity and diabetic epidemics means that DHF is a major public health problem. DHF, similar to systolic HF has a five-year mortality rate of 65%. In many of these patients, diastolic dysfunction caused by hypertensive heart disease (HHD) is implicated as a major contributor, if not a primary cause. Furthermore, the prevalence of asymptomatic diastolic dysfunction in the community is significant with approximately 25-30% of individuals >45 years of age being affected. There are no proven, life-saving therapies for treating DHF. Many of the well-established drug therapies for systolic heart failure have been directed at DHF without success. The diagnosis of DHF can present a challenge in routine clinical practice. The major limitation in the diagnosis of DHF is the identification of diastolic dysfunction (DD), which at present is predominantly reliant on Doppler echocardiographic studies. Echocardiography has been used for many years to provide structural correlates to the clinical picture of HF. It can also measure multiple clinically important parameters of cardiac function, including hemodynamic status and LVEF, volumes and mass. The pathophysiology of DHF includes delayed relaxation, impaired LV filling and/or increased stiffness. These conditions result in an upward displacement of the diastolic pressure-volume relationship with increased end-diastolic, left atrial and pulmo-capillary wedge pressure leading to symptoms of pulmonary congestion. Diagnosis of DHF requires three conditions; (1) presence of signs or symptoms of HF; (2) presence of normal or slightly reduced LVEF (>50%) and (3) presence of increased diastolic filling pressure. Data indicate that the underlying pathophysiology in diastolic dysfunction and DHF is related to myocardial interstitial disease. Collagen is a stable protein and its balanced turnover is estimated to be 80-120 days. Alteration of collagen turnover by various mechanisms can lead to adverse accumulation of collagen in the myocardial interstitium leading to fibrosis, increased tissue stiffness, reduced myocardial compliance and impaired diastolic function. The successful neurohumoral-based approach to pharmacotherapy in HF with systolic dysfunction has not resulted in similarly impressive results in HFpEF, implicating additional pathophysiological signals. Changes in the extracellular matrix (ECM), known as myocardial remodeling, are central abnormalities in many patients with HFpEF and are characterized by inflammation, increased ECM turnover and myocardial fibrosis. Key mediators of inflammation are pro-inflammatory cytokines including interleukins (IL) (IL-1β, IL-6, IL-8) and tumor necrosis factor (TNF)α. Key regulators of the turnover of collagen and extracellular matrix (ECM) in the myocardium are the matrix metalloproteinases (MMPs) and their tissue inhibitors (TIMPs). MMPs in particular have been found to play an important role in both inflammation and fibrosis. MMPs also contribute to collagen degradation and remodeling of the ECM after myocardial infarction. ECM turnover is regulated by matrix metalloproteinases (MMPs), especially the “gelatinases”, MMP-2 and MMP-9, and their tissue inhibitors (TIMPs). MMP-2 and MMP-9 knockout models are associated with reduced aortic elastin degradation and protection from pressure overload hypertrophy, fibrosis and dysfunction. In the clinic, independent associations between ALVDD and HFpEF have been identified with markers of inflammation, fibrosis and MMP-9. During ischemic cardiomyopathy, neutrophil proteinase activates latent myocardial MMP, which can degrade the ECM. If unchecked by TIMPs, the ECM continuously degrades, leading to ventricular dilatation and diastolic dysfunction. Despite the emerging awareness of the potential role of collagen metabolism in the pathogenesis of diastolic HF there are as yet no effective therapies for this form of HF. Pharmacological modulation of MMPs may present an opportunity. However, all MMP synthetic inhibitors developed to date have either been ineffective or demonstrated dose- and duration-dependent drug-related side-effects, most which were musculoskeletal-related. Despite some promising animal studies of MMP inhibitors showing attenuation of cardiovascular remodeling in chronic pressure-overload models, the approach of direct inhibition of MMP enzymes has proven too toxic or ineffective in the clinic. An alternative approach in cardiovascular disease would inhibit production and/or secretion of inducible myocardial MMP-9. As well as classic inflammatory diseases such as rheumatoid arthritis, hay fever, periodontitis, inflammation plays an important role in the development and progression of diabetes and a variety of cardiovascular conditions, most notably coronary atherosclerosis and congestive heart failure. The term “Diabetic cardiomyopathy” was coined 4 decades ago and describes a “silent, stiffening” of the heart tissue which can lead to heart failure. There are no symptoms until heart failure occurs. It is present in half of people with diabetes and is more prevalent than well-recognised “silent pumping problem” which has good treatment available. This silent stiffening of the heart is linked to overweight, diabetes, high blood pressure and there are no specific therapies. Over the past 20 years, basic and human research has shown that enzymes in the heart called matrix metallproteinases or MMPs are involved in the stiffening process. They also affect large and small blood vessels and cause eye and kidney damage in diabetes. For example, in patients with diabetic retinopathy, increased MMP-9 activity was observed in retinal microvessels and MMP-9 knockout was protective (Kowluru et al, Abrogation of MMP-9 Gene Protects Against the Development of Retinopathy in Diabetic Mice by Preventing Mitochondrial Damage. Diabetes. 2011 Sep. 20 [Epub ahead of print]). Increased urinary excretion of MMP-9 in patients supports a role for MMP-9 dysregulation in diabetic renal dysfunction (Thrailkill et al., Endocrine. 2010 April; 37(2):336-43). Aortic and coronary arteries of diabetic patients taken at autopsy had higher expression of MMP-9 compared to non-diabetics and were correlated with HbA1c as well as apoptosis (Ishibashi et al., J Atheroscler Thromb. 2010 Jun. 30; 17(6):578-89). Elevated MMP-9 has also been associated with arterial stiffness in patients with diabetes (Chung et al., Cardiovasc Res. 2009 Dec. 1; 84(3):494-504). Furthermore, human genetic polymorphisms associated with MMP-9 elevation support a role for this enzyme in the pathophysiology of vascular disease. The 1562C>T single nucleotide polymorphism (SNP), which affects the promoter region of MMP-9 gene and increases circulating levels of MMP-9, is significantly associated with vascular disease in type 2 diabetes mellitus (Wang et al., Biochem Biophys Res Commun. 2010 Jan. 1; 391(1):113-7). In age and sex matched controls, patients with type 2 diabetes without and with microangiopathy, T allele frequencies were 11.9%, 13.1% and 24.4% respectively (p<0.05). Similarly, in a cohort of asymptomatic hypertensive patients, the 1562C>1 polymorphism is associated with increased T allele frequency, higher plasma MMP-9 and evidence of increased hypertension and vascular stiffness, measured by pulse wave velocity (Zhou et al. J Hum Hypertens. 2007 November; 21(11):861-7). Inflammation is also involved in the development and progression of some cancers (e.g., gallbladder carcinoma). Inflammation is mediated by a complex interplay of mediators such as IL-1 beta, IL-4 and IL-8. IL-1 beta induces COX-2, which causes brain levels of prostaglandin (PG)E2 to rise, thus activating the thermoregulatory center for fever production. In the periphery, IL-1 beta activates IL-1 receptors on the endothelium, resulting in expression of adhesion molecules and chemokines, which facilitate the emigration of neutrophils into the tissue spaces. IL-1 is pro-inflammatory and has been implicated in various pro-inflammatory diseases such as coronary atherosclerosis and congestive heart failure as well as diabetes where recent studies from animals, in-vitro cultures and clinical trials provide evidence that support a causative role for IL-1β as the primary agonist in the loss of beta-cell mass in type 2 diabetes. IL-4 is a TH2 type anti-inflammatory and profibrosis cytokine that stimulates and amplifies the inflammatory response by activation of the synthesis of types I and II collagen by fibroblasts and the promotion of the progression of fibrosis. IL-4 also inhibits the proinflammatory response of TNF-α, IL-1 and IL-6. IL-4 stimulates inflammatory responses, activates collagen synthesis, promotes fibrosis progression, and inhibits the production of inflammatory cytokines. The patients with CHF had higher IL-4 and PIIINP values than the controls. Comparison of the IL-4 values between the patients and controls showed a significantly greater difference in the CHF patients (12 [12] vs 4 [3] pg/mL; P<0.0001). Recent studies have shown that pro-inflammatory cytokines play a significant contributory role in the pathogenesis of acute heart failure. The purpose of this study was to determine whether the serum IL-8 concentration in patients with acute myocardial infarction (AMI), who were undergoing percutaneous coronary intervention (PCI) was related to the subsequent presence or absence of heart failure. A study by Dominguez-Rodriguez 2006, included 50 patients who underwent successful PCI. During their subsequent stay in the coronary care unit, their maximum degree of heart failure was recorded. Serum levels of IL-8 in patients more severe symptoms (Killip class >I) were significantly higher than those of with less severe symptoms (Killip class I) (P<0.001). By multivariante analysis a higher level of IL-8 was a significant predictor of heart failure after PCI. Similarly in HF, the presence of the metabolic syndrome which puts patients at higher risk, plasma levels of IL-8 (p<0.05) were significantly higher in HF patients with MetS than those without MetS.
Tetracyclines, commonly known for their broad-spectrum antimicrobial properties, have been characterized as pleiotropic immunomodulatory agents. In human studies, sub-antimicrobial doses of the tetracycline, doxycycline, have exerted potentially beneficial effects on inflammation that could promote plaque stability in an effort to prevent acute coronary syndrome, as doxycycline therapy has been shown to lead to a powerful reduction of aneurysmal wall neutrophil and cytotoxic T-cell count; two cell types considered crucial for the process of aneurysm formation. Attempts have been made to attenuate MMP expression to inhibit aortic abdominal aneurysm formation using doxycycline, thereby reducing the need for surgery. Doxycycline has been shown to inhibit secretion of MMP-2 and MMP-9 and is the only drug currently licensed for human use that relies on MMP inhibition. It is currently under evaluation in ALVDD and HF patients in our group for its effects on inflammation, MMPs, myocardial structure and function using cardiac MRI [EudraCT number: 2010-021664-16]. However, in several animal and human studies, the efficacy of MMP inhibition with doxycycline has been questioned. This may reflect non-specific inhibition of the wider MMP family with high doses and/or chronic therapy, involving inhibition of both constitutive and inducible enzymes. It prompted our group to create analogues of doxycycline that target over-expression of inducible MMP-9 rather than direct enzyme inhibition as a more effective and safer approach. Evidence is emerging that members of the MMP and/or A disintegrin and metalloproteinase (ADAM) family can serve not only as potential markers for diagnosis and prognosis, early detection, and risk assessment, but also as indicators of tumor recurrence, metastatic spread, and response to primary and adjuvant therapy for breast cancer. MMP-9 levels in tumor tissue as well as serum, plasma, and urine are significantly elevated in patients with breast cancer. Recently, efforts have focused on the use of MMPs and ADAMs as potential biomarkers of early breast cancer. Studies indicate that urinary MMP-9 and ADAM12, in addition to being predictive markers for breast cancer, may also prove useful as noninvasive breast cancer risk assessment tools. Several independent studies have used circulating MMP-9 activity to predict metastatic spread of disease as well as to monitor patient response to primary and adjuvant therapy and to evaluate outcome. High levels of serum MMP-9 and TIMP-1 are associated with increased incidence of lymph node metastasis and decreased relapse-free and overall survival rates. MMPs may also be useful in predicting therapeutic efficacy. Plasma MMP-9 levels decrease after the surgical removal of primary breast tumors and a progressive decrease in plasma MMP-9 was observed in patients who responded well to adjuvant therapy. Importantly, in all patients who suffered a relapse of disease there was a gradual increase of plasma MMP-9 activity 1 to 8 months before the clinical diagnosis of recurrence. Serum and tissue levels of MMP-9 are significantly higher in patients with pancreatic ductal adenocarcinoma than in patients with chronic pancreatitis and healthy controls. Active MMP-2 levels are upregulated in the pancreatic juice of patients with cancer (100%) as compared with patients with chronic pancreatitis (2%) or normal controls (0%). Several studies have reported that plasma and/or serum levels of MMP-9 and TIMP-1 are elevated in patients with stage III or IV lung cancer when compared with those in patients with nonmalignant lung diseases. Urinary MMP-2 and MMP-9 levels correlate with presence of bladder cancer as well as stage and grade of disease. Several MMP species have been reported in urine from patients with primary tumors in the bladder and prostate including MMP-2, MMP-9, MMP-9/neutrophil gelatinase-associated lipocalin complex and MMP-9 dimer. Each urinary MMP species was detected at significantly higher rates in urine from patients with cancer as compared with controls. The difference in detection of MMP species in the urine of the two types of cancers studied may serve as a tumor-specific fingerprint that can indicate both the presence of a tumor as well as its location. Increased levels of MMP-9 and MMP-2 in urine correlate with increased expression of these proteases in bladder tumor tissue as well. Urinary MMP-9 levels when combined with telomerase analysis of exfoliated cells from voided urine could also increase the sensitivity of cytology, a commonly used method for bladder cancer detection and monitoring. MMP-2 and MMP-9 have been studied as potential prognostic biomarkers of colorectal cancer. Enhanced MMP-9 staining in primary tumors was found to be an independent marker of poor prognosis in a study with T3-T4 node-negative patients. Plasma MMP-2 and MMP-9 levels were significantly elevated in patients with colorectal cancer and those with adenomatous polyps, and significant reduction in both were observed after tumor resections, suggesting their potential as markers for therapeutic efficacy. These MMPs may not be prognostic markers for tumor recurrence, however, since plasma proMMP-2 and -9 activities did not correlate with disease relapse after surgery. Tutton and colleagues investigated whether plasma MMP-2 and MMP-9 levels could be used as a surrogate for tumour expression in colorectal cancer patients and they found significant correlations between plasma levels and tumor pre- and post-op. MMP-2, -9, and -14 are among the most studied MMPs as biomarkers for ovarian cancer. MMP-9 activity in tissue extracts was significantly increased in advanced ovarian cancers (International Federation of Gynecology and Obstetrics stage III) compared with benign tumors and was found to be an independent prognosticator of poor survival. In another study of invasive epithelial ovarian cancer, high stromal expressions of MMP-9 and -14 were significantly correlated with cancer progression and were independent prognostic markers. Tissue MMPs have also been shown to distinguish different histotypes of ovarian cancer, which is a significant finding given that different histotypes have different prognoses. A recent study showed that more than 90% of clear-cell carcinomas expressed moderate to high levels of MMP-2 or MMP-14, compared with 30% to 55% of the other ovarian cancer histotypes (serous, endometroid, and mucinous), whereas MMP-9 was expressed more widely in other histotypes. Importantly, the cellular source of MMPs must be considered when evaluating MMPs as ovarian cancer biomarkers. For example, strong MMP-9 levels in cancer cells were associated with longer survival whereas strong stromal MMP-9 was associated with shorter survival, suggesting a dual role for MMP-9 during ovarian cancer progression. MMP-2, -9, -15, and -26 expression in tissue or serum have been positively correlated with Gleason score in prostate cancer. Among these MMPs, the activities of plasma MMP-2 and -9 increased significantly in metastatic prostate cancer. Analysis of MMP-2 and -9 levels in radical prostatectomy specimens revealed these two as significant predictors of cancer recurrence. These two enzymes may also be markers of therapeutic efficacy, since both the levels and activities of plasma MMP-2 and -9 decreased significantly in metastatic patients after therapy. In addition, increased urinary MMP-9 activity has been shown to distinguish between prostate and other types of cancer (e.g. bladder cancer). MMPs can also be combined with other markers to increase their predictive capability. For example, the mRNA ratio of gelatinases to E-cadherin in biopsy samples independently predicted prostate cancer stage. Elevated tissue levels of MMP-2 and MMP-9 have been reported in aggressive brain tumors. Both latent and activated forms of MMP-2 and MMP-9 have been detected in the cerebrospinal fluid of patients with brain tumors. In studies of primary glial tumors and other central nervous system tumors, we have recently shown that detection of MMP-2, MMP-9, MMP-9/neutrophil gelatinase-associated lipocalin complex, and/or vascular endothelial growth factor in the urine predicted disease status and therapeutic efficiency of patients with brain cancer. Importantly, these studies showed that the upregulation of MMP-2 and -9 in the source tumor tissue was also reflected in CSF as well as in urine of these patients. Tumor cells overexpress proteases and/or induce expression of these enzymes in neighboring stromal cells in order to degrade the basement membrane and invade the surrounding tissue. Several MMPs have been implicated in the ECM degradation associated with tumor growth and angiogenesis. This proteolytic activity is also required for a cancer cell to invade a nearby blood vessel (intravasation) and then extravasate at a distant location and invade the distant tissue in order to seed a new metastatic site. MMPs have been shown to promote angiogenesis through their release of angiogenic factors stored in the ECM such as vascular endothelial growth factor (VEGF) and basic fibroblast growth factor (bFGF; 3). Stroma-derived MMP-9 can facilitate the liberation of ECM-sequestered VEGF during tumor angiogenesis. MMPs play complex and sometimes conflicting roles in regulating angiogenesis. Remodeling of the ECM during angiogenesis is accomplished largely through the activity of MMPs. Angiogenic mitogens, such as bFGF and VEGF, can stimulate the production of MMPs by capillary endothelial cells. Studies have also demonstrated that MMPs are involved in the angiogenic switch, one of the earliest stages of tumor growth and progression. It has been shown that MMP-9 can be a regulator of the angiogenic switch in a pancreatic tumor model, further confirming the pro-angiogenic role of MMPs. These findings strongly suggest that MMP activity is critical, not only to the initiation of angiogenesis, but to the maintenance of the growing vascular bed, which in turn supports tumor growth and metastasis. MMP activity can, however, result in the production of negative regulators of angiogenesis as well. ECM degradation products display unique biologic properties that can trigger a variety of cellular signals. MMPs have also been implicated in the epithelial to mesenchymal transition (EMT), a hallmark of cancer progression to metastasis. Activation of growth factors and cleavage of adhesion molecules are some of the proposed mechanisms underlying MMP-induced EMT. Recent studies point to an emerging role for MMPs in modulating aspects of immunity and inflammation during tumorigenesis. A variety of cytokines, cytokine receptors, and chemokines have been found to undergo MMP-mediated cleavage. In breast cancer, MMP-9 expression is upregulated in tumor-associated stromal cells including neutrophils, macrophages, and lymphocytes and may play a role in tumor-associated inflammation. Several members of the MMP and ADAM family can regulate cellular proliferation by modulating the bioavailability of growth factors or cell-surface receptors. Ligands for several growth factor receptors are processed by MMP/ADAM family members as well. There are known clinical benefits of MMP inhibition in cancer management (for example Neovastat (AstraZeneca) is currently under evaluation in phase II renal cell carcinoma). However, most MMP inhibitors are too toxic for use in the clinic and adverse effects of MMP inhibitors (e.g. musculoskeletal adverse effects) limit their use. Furthermore, there may be problems with potent, broad spectrum, MMP inhibition. For example, there are some data suggesting that tumour progression is inversely proportional to MMP-3. Accordingly, it is not known if MMP-3 sparing or MMP-3 inhibiting effects are preferable. Recent developments in anti-cancer agents targeting the matrix metalloproteinases have been reviewed (Li, et al., Recent Patents on Anti - Cancer Drug Discovery 2010, 5: 109-141) and show that MMP inhibitors are classified into three main pharmacologic categories: Collagen peptidomimetics, non-peptidomimetics and tetracycline derivatives. Collagen peptidomimetics can be further subdivided into hydroxamates, carboxylates, aminocarboxylates, sulfhydryls, phosphoric acid derivatives. Most MMP inhibitors in clinical development are hydroxamate derivatives, e.g. batimastat and marimastat, illomastat. The lead compounds have been largely unsuccessful because of toxicity and or lack of efficacy. For example, Batimastat can only be administered intraperitoneally and intrapleurally and further development has been suspended. In the case of Marimastat, no benefit over placebo was seen in patients with breast and lung cancer. Severe musculoskeletal pain occurred in 18% of patients and quality of life worsened with marimastat therapy. Development of this drug has also been discontinued. Several members of the non-peptidomimetics class of compounds are undergoing evaluation in Phase III studies in cancer patients. However, the majority are no longer in development because of an adverse efficacy/toxicity profile (including AG3340/Prinomastat (Agouron), BMS-275291 (Bristol-Myers-Squibb), CGS27023A/MMI270 (Novartis), Bay12-9566/Tanomastat (Bayer Inc). Neovastat/AE-941 (Aetherna Zentaris) has MMP-2, MMP-9 and VEGF inhibitory properties and is being evaluated as a potential treatment of renal carcinoma and Phase II clinical trials are underway. Some tetracycline derivatives, such as doxycycline and COL-3 have been evaluated in preclinical cancer models and G 31 have entered early clinical trials in patients. Doxycycline has been shown to substantially reduce the tumor burden from breast cancer metastasis in nude mice. It exerts diverse inhibitor effects on MMP production and activity, inhibits tumor cell proliferation. However, it accumulates at high concentrations in bone, and can therefore be used for the treatment of bone metastasis. Inhibition of mitochondrial protein synthesis by doxycycline has significant anti-tumor effects in several tumor systems. Continuous doxycycline treatment combined with intermittent administration of adriamycin or 1-beta-D-arabinofuranosyl cytosine on the growth of rat leukemia resulted in the delay of tumor relapse. Treatment with zoledronic acid in combination with doxycycline may be very beneficial for breast cancer patients at risk for osteolytic bone metastasis, according to the fact that administration of a combination of zoledronic acid and doxycycline resulted in a 74% decrease in total tumor burden compared to untreated mice. In addition, doxycycline significantly enhances the tumor regression activity of cyclophosphamide, a widely used chemotherapeutic drug in neoplasias, on xenograft mice model bearing MCF-7 cells, suggesting that such combination chemotherapeutic regimen may lead to additional improvements in treatment of breast cancer. In vivo, the inhibitory effects of doxycycline on breast cancer tumor matastasis formation was potentiated by the addition of batimastat, confirming that targeting MMPs through multiple distinct pathways may improve treatment efficacy. However, in a Phase I evaluation of cancer patients, oral doses of 400 mg administered twice a day resulted in dose-limiting toxicity that consisted of fatigue, confusion, nausea, and vomiting. At the maximum tolerated dose of 300 mg twice a day, mean through plasma concentrations were comparable to those associated with antiangiogenic effect in vivo.
Nitric oxide is a gaseous molecule that is unsuitable for oral administration. However, there are several pharmacologically relevant nitric oxide-donor groups than are known to release nitric oxide in response to conditions found in the human body after administration. Exemplary nitric-donor groups are described in “Nitric Oxide Donors: For Pharmaceutical and Biological Applications”; Peng George Wang, Tingwei Bill Cai, Naoyuki Taniguchi, Wiley (2005), the contents of which are incorporated herein by reference. The effects of nitric oxide on MMPs are complex. Nitric oxide has been reported to possess inhibitory effects on MMP-9 by destabilization of MMP-9 RNA and through effects on MMP-9 activating cytokines, secondary messengers and transcription factors (AP-1). In contrast higher concentrations of nitric oxide have been shown to cause MMP activation through S-nitrosylation of an inhibitory cysteine on the prodomain.
Abbreviations: ALVDD=Asymptomatic left ventricular diastolic dysfunction, AUC=Area under the curve, cGMP=Cyclic guanosine monophosphate, DMSO=Dimethyl supfoxide, DNA=Deoxyribonucleic acid, ECM=Extracellular matrix, FCS=Fetal calf serum, HCF=Human ventricular cardiac fibroblasts, HF=Heart failure, HFpEF=Heart failure with preserved ejection fraction, IF=Interferon, iNOS=Inducible nitric oxide synthase, IQR=Interquartile range, MCP=Monocyte chemotactic protein, MMP=Matrix metalloproteinase, MRI=Magnetic resonance imaging, mRNA=messenger ribonucleic acid, NHP=Non-human primate, NO=Nitric oxide, PBMC=Peripheral blood mononuclear cells, PCR=Polymerase chain reaction, RAAS=Renin-angiotensin-aldosterone system, RNA=Ribonucleic acid, SEM=Standard error of the mean, TIMP=Tissue inhibitor of matrix metalloproteinase, TNFα=Tumor necrosis factor alpha.
SUMMARY OF THE INVENTION
According to a first aspect of the present invention, there is provided a combination of a:
a first tetracycline (TC) component; and
a second component capable of releasing nitric oxide (NO) or a nitrate capable of mimicking NO effects in vivo (NO mimetic)
Nitric oxide (NO) is a gaseous molecule that is unsuitable for oral administration. There are several pharmacologically relevant groups than are known to liberate nitric oxide in response to conditions found in the human body after administration or known to mimic nitric oxide's actions, for example, by stimulating cGMP production. The nitrate capable of mimicking NO effects in vivo do not necessarily release NO, but may mimic NO effects in the body with actual release of NO from the second component. For example, one simple NO mimicry effect in vivo is the activation of soluble guanyl cyclase (sGC) leading to elevated cGMP. The inventors have found that combinations of tetracyclines and nitric oxide donors or nitric oxide mimetics such as organic nitrates have favourable effects on MMP expression in vivo. It has been found that nitric oxide release or mimicry through sGC activation when combined with tetracyclines can achieve clinically relevant improvements in MMP modulation efficacy and selectivity relative to tetracyclines by themselves. The combinations of the invention advantageously act as effective MMP modulators (with inhibitory effects on MMP-2 and MMP-9, in particular), and/or modulators of inflammation mediators. Therefore, the various combinations of the invention find utility in medical applications where MMPs and/or inflammation is implicated. Included are, for example, myocardial interstitial disease, cardiac fibrosis, heart failure such as heart failure with diastolic heart failure (DHF), heart failure with preserved ejection fraction (HFpEF), congestive heart failure (CHF), asymptomatic left ventricular diastolic dysfunction (ALVDD), coronary atherosclerosis (inflammation effects), cancers (through effects on tumor angiogenesis, tumor growth and metastasis) and diabetes (inflammation effects). In addition, the combinations of the invention are useful in other inflammatory diseases or diseases associated with inflammation, including but not limited to, inflammatory bowel disease, chronic prostatitis, infections, pulmonary inflammation, osteomyelitis, renal disease, gout, arthritis and shock.
The term “combination” is intended to cover related aspects of the invention wherein (i) the first and second components are associated together through a chemical interaction, such as a covalent bond or an electrostatic interaction or a linker group to form a compound comprising both tetracycline and component capable of releasing nitric oxide (NO) or mimicking its effects (NO mimetic), or (ii) the tetracycline component and the component capable of releasing nitric oxide (NO) or NO mimetic are provided in the form of an admixture of both components, for example, in a single dosage unit; or (iii) the tetracycline component and the component capable of releasing nitric oxide (NO) or NO mimetic, are provided in the form of two or more compositions, for example, separate dosage units, suitable for administration to a patient to provide the desired therapeutic effect.
By “capable of releasing nitric oxide”, it is meant the dissociation or release in vivo of a nitric oxide molecule from the compound of the invention, such that the nitric oxide component is no longer associated with, or linked to the tetracycline component or it is meant that the component can mimic NO's effects in vivo such as through activation of sGC.
By “nitric oxide releasing group” or NO mimetic, it is meant a polyatomic substance comprising at least one group capable of releasing nitric oxide or mimicking its effects. Such as group may be a nitrate ester of an alkyl alcohol (organic nitrate). Alternatively the nitric oxide donor or mimetic group may be the conjugate base of nitric acid (nitrate ion). As explained above, second component molecules comprising other nitric oxide mimetic or donor groups are also possible and include nitrate ester, diazeniumdiolates, N-diazen-1-ium-1,2-diolate (NONOate), S-nitrosothiols, furoxan or L-arginine which is a substrate for nitric oxide synthase. Clinically used nitric oxide mimetic or donor groups that may suitably be used in the combinations of the invention include isosorbide dinitrate, isosorbide 2- and 5-mononitrate, erithrityl tetranitrate, penterithrityl tetranitrate, nicorandil, sinitrodil, glyceryl trinitrate. Preferred “nitric oxide releasing group” or NO mimetics are is arginine, a metal nitrate salt or an aza-C 1 to C 5 alkyl, aza-C 1 to C 5 alkenyl, or aza-C 1 to C 5 alkynyl groups or a hetrocyclic amine group, which is substituted with at least one NO releasing group. Preferably the “nitric oxide releasing group” or NO mimetic is nitrate. In this embodiment, the preferred nitrate esters are selected from H 2 N-Et-ONO 2 , HN-(Et-ONO 2 ) 2 , MeNH-Et-ONO 2 , Me 2 N-Et-ONO 2 , H 2 N-pentyl-ONO 2 or H 2 N-cyclopentyl-ONO 2 ,
By “associated with” is meant that the tetracycline and the group or molecule capable of releasing nitric oxide (NO) are associated, or linked together by at least one chemical interaction. For example, an ionic or electrostatic interaction, a covalent or a donor bond interaction. This functional group may be involved in at least one of these types of chemical interaction with the tetracycline component either directly through covalent bonding or through electrostatic interactions, or indirectly through a linker component, such as a linker group or molecule, for example, a chemical functional group or molecule.
In a first aspect, the combination of the invention concerns a compound comprising the first and second components. In a second aspect, the combination of the invention concerns an admixture of at least one of the first and at least one of second components. In a third aspect, the combination of the invention concerns two or more separate compositions of at least one of first and at least one of the second components for administration. Accordingly, the second component may be mixed with, administered with, bonded or linked with the first tetracycline component as described above for the purposes of the combinations of the present invention.
Preferably, the combination is a compound in which the first and second components are associated together through a chemical interaction, such as a covalent bond or an electrostatic interaction or a linker group to form a compound comprising both tetracycline and component capable of releasing nitric oxide (NO) or mimicking its effects (NO mimetic).
In this embodiment, the components are associated together through a chemical interaction, such as a covalent bond or an electrostatic interaction or a linker group to form a compound comprising both tetracycline and component capable of releasing nitric oxide (NO) or mimicking its effects (NO mimetic). Suitably, the linker is a methylene (—CH 2 —), or methylene substituted with a methyl, ethyl or propyl group (—CHMe-, —CHEt- or CHPr—).
Accordingly, in the first aspect, the compound of the invention comprises a first tetracycline component having general formula:
in which
R 1 is —H or —OH; R 2 is —H, —OH or -Me; R 3 is —H, or —NMe 2 ; R 4 is —H, —OH or -Me; and R 5 is —H or —OH. Preferably, when R 2 is —H or Me, R 4 is —OH.
Preferably, the tetracycline may be selected from the group consisting of: tetracycline, minocycline, doxycycline and oxytetracycline. The structures of these tetracyclines are:
In a particularly preferred embodiment, the tetracycline may be doxycycline, doxycycline hyclate or doxycycline hydrochloride.
In the first aspect, in which the combination of the invention concerns a compound, the second component is designated herein as the “associated molecule” or as the “second component”. The second component is either capable of mimicking NO's effects in vivo, capable of releasing nitric oxide spontaneously, or is capable of releasing nitric oxide (NO) through metabolism to form nitric oxide or at least one of its redox congeners. Preferred redox congeners of nitric oxide include any reduced form of nitric oxide (NO). They may be selected from nitroxyl anion (NO − ), NO radical (NO.) and nitrosonium cation (NO + ═N≡O + ). The skilled person will appreciate that the form of nitric oxide redox congener produced will depend on various enzymatic or non-enzymatic metabolic pathways involved in any particular nitric acid metabolism of the compounds of the invention. Preferably, in this embodiment, the second component comprises at least one functional group comprising N(O) n which is associated with the tetracycline; wherein n is an integer selected from 1-3. Suitably, the at least one functional group comprising N(O) n is capable of releasing nitric oxide (NO) or acting as an NO mimetic. Preferably n is 3. Suitably, the second component forms at least one chemical bond with the tetracycline component of the compound of the invention. Preferable the chemical bond may be a covalent, a polar covalent bond or a donor (coordinate) bond between the first and second components. Preferably, the bond is a covalent bond. Alternatively, the second component may be associated, or linked, directly with the first tetracycline component through an electrostatic or ionic interaction.
Further alternatively, the second component may be associated, or linked, with the first tetracycline component through a linker group or molecule, which are described below in more detail.
Accordingly, in the first aspect, wherein the combination of the invention concerns a compound, the compound comprises:
a first tetracycline (TC) component; and
a second component capable of releasing nitric oxide (NO) or mimicking nitric oxide (NO);
wherein the second component is ionically or covalently bonded to the first component, or is linked thereto, by means of a linker atom or molecule. Preferably, the second component is covalently bonded to the first component. More preferably still, the second component is linked to the first component by a linker atom or molecule. Preferably, the second component comprises at least one functional group having N(O) n , wherein n is 3. In this embodiment, the at least one functional group comprises a nitrate anion (NO 3 − ). Alternatively, the functional group comprises a nitrate group (—ONO 2 ). Nitrate compounds are particularly preferred because of their clinical use, stability and lipophilicity.
In a preferred embodiment of the first aspect of the invention, the compound is a tetracycline nitrate ester, in which nitrate is directly bonded to the tetracycline component. In this embodiment, the compound of the invention takes the form tetracycline (TC)—NO 2 , where no linker group or molecule is required. For example, the compound of the invention is doxycycline nitrate, structure shown below. The skilled person will appreciate where the nitrate group can be directly bonded to the tetracycline in this embodiment.
Alternatively, the linker group may be a compound forming a Mannich base attachment to the tetracycline (TC-M-ONO 2 ). Where a linker group is used, more than one nitrate can be appended onto the linker, for example, (TC-M-(ONO 2 ) 2 ). Finally, the second component molecule may simply be the counter anion (ONO 2 ), wherein an ionic interaction between a cationic form of the tetracycline (TC + ) and the nitrate anion provides the basis for the association between the TC and second component of the compound of the invention. The Mannich base is formed by reaction of the amide group of the first tetracycline component with formaldehyde or an aldehyde to form an imine, which is subsequently reacted with an amine forming a Mannich base derivative. Alternatively the TC can be reacted with an immine formed by reacting an aldehyde with amine. In this embodiment, the compound of the invention takes the form tetracycline (TC)-M-ONO 2 , where M represents the Mannich base attachment or the linker group created by the Mannich base attachment (for example, methylene (—CH 2 —), or methylene substituted with a methyl, ethyl or propyl group (—CHMe-, —CHEt- or CHPr—), etc, depending on the aldehyde used in the Mannich base reaction), which leads to insertion of the linker group. The Mannich base attachment is to the primary amide of the tetracycline of the invention. The skilled person will appreciate that then, for example, an aldehyde such as paraformaldehyde is used to form the Mannich base linkage, the reaction inserts a methylene group between the first and second components of the compound of the invention. This methylene group then serves as a linker associating the first and second components together by covalent bonding. Different types of methylene linkers with different substitutions may be used by selection of appropriate aldehyde.
Accordingly, in a second embodiment of the first aspect, wherein the combination of the invention concerns a compound, the second component comprises:
(i) a short chain aza-alkyl (C 1 to C 5 ), aza-alkenyl (C 1 to C 5 ), or aza-alkynyl (C 1 to C 5 ) group, which can be linear, branched, or cyclic; and
(ii) at least one nitric oxide donor group or NO mimetic selected from a nitrate ester, diazeniumdiolates a N-diazen-1-ium-1,2-diolate (NONOate), S-nitrosothiols, furoxan or a molecule capable of releasing nitric oxide (NO), such as arginine or similar nitric oxide releasing moiety or mimetic.
In this embodiment, the second component may be bonded or linked to the first tetracycline component through its primary amide by a covalent bond giving a compound with general structure:
in which R is one of the aza-alkyl (C 1 to C 5 ), aza-alkenyl (C 1 to C 5 ), or aza-alkynyl (C 1 to C 5 ) groups or fragments described above, Tc is the first tetracycline component, and L is a methylene linker, which can be unsubstituted (—CH 2 —) or substituted with a methyl, ethyl or propyl group (—CHMe-, —CHEt- or CHPr—). The substitution on the methylene linker depends on the aldehyde used in the Mannich base reaction. Examples of the second compound include nitrated aza-alkyl, nitrated aza-alkenyl, or nitrated aza-alkynyl groups
In a second embodiment of the first aspect of the invention, the second component comprises:
(i) a short chain aza-alkyl (C 1 to C 5 ), aza-alkenyl (C 1 to C 5 ), or aza-alkynyl (C 1 to C 5 ) group or fragment, which can be linear, branched, or cyclic, and which can be substituted or unsubstituted; and
(ii) at least one nitric oxide donor or mimetic group or at least one group comprising N(O) n , wherein n is an integer selected from 1-3, as defined above, hereinafter referred to as a ¢nitric-oxide donor group”.
Examples of the second component include aza-(C 1 to C 5 )alkyl, aza-(C 1 to C 5 )alkenyl aza-(C 1 to C 5 )alkynyl group or fragment which is substituted with at least one nitrate. Preferred examples of the second component include nitrated aza-alkyl, wherein the second component is a nitrated C 1 to C 5 alkyl amine, more preferably, a nitrated C 1 to C 2 alkyl amine. Preferably, the nitrated aza-alkenyl is a nitrated C 1 to C 5 alkenyl amine, more preferably a nitrated C 1 to C 2 alkenyl amine. Preferably, the nitrated aza-alkynyl group is a nitrated C 1 to C 5 alkynl amine, more preferably a nitrated C 1 to C 2 alkynl amine. Preferred examples of the second component comprises a short chain aza-alkyl (alkyl amine) molecule H 2 N—R, in which R is a C 1 -C 5 alkyl group, more preferably a C 1 -C 2 alkyl group. Preferably, the nitric oxide donor or mimetic group is —ONO 2 . Examples of the second component are be H 2 N—R—N(O) n , in which R is a C 1 -C 5 alkyl, alkenyl or alkenyl more preferably a C 1 -C 2 alkyl alkyl, alkenyl or alkenyl. The nitric oxide donor or mimetic group in this example is preferably —ONO 2 .
In this embodiment, the second component is linked to the first tetracycline component by a Mannich base attachment through a linker L to the amide group of the first tetracycline component, giving a compound with general structure:
in which R is a aza-alkyl (C 1 to C 5 ), aza-alkenyl (C 1 to C 5 ), or aza-alkynyl (C 1 to C 5 ) group or fragment, Tc is the first tetracycline component, and L is a methylene linker, which can be unsubstituted methylene (—CH 2 —) or substituted with a methyl, ethyl or propyl group (—CHMe-, —CHEt- or CHPr—).
In a third embodiment of the first aspect of the invention, the second component may be linked to the first tetracycline component by a Mannich base attachment through a linker group L to the amide group of the first tetracycline component, forming a compound with general structure:
wherein R is an aza-alkyl (C 1 to C 5 ), aza-alkenyl (C 1 to C 5 ), or aza-alkynyl (C 1 to C 5 ) group or fragment, Tc is the first tetracycline component, and L is a methylene linker. The methylene linker may be unsubstituted (—CH 2 —) or substituted with a methyl, ethyl or propyl group (—CHMe-, —CHEt- or CHPr—). The substitution depends on the aldehyde used in the Mannich base reaction.
In a fourth embodiment of the first aspect of the invention, the second component comprises:
(i) an aza-ethyl molecule (ethyl amine, EtNH 2 ); and
(ii) at least one nitrate (—ONO 2 ) group.
Typical examples of second component molecules are H 2 N-Et-ONO 2 .
In this embodiment, the second component is linked to the first tetracycline component by a Mannich base attachment through a linker L to the amide group of the first tetracycline component, forming a compound with general structure:
in which Tc is the first tetracycline component, and L is a methylene linker. The methylene linker may be unsubstituted (—CH 2 —) or substituted with a methyl, ethyl or propyl group (—CHMe-, —CHEt- or CHPr—).
In a preferred fifth embodiment of the first aspect, the second component comprises:
(i) an aza-dimethylethyl molecule (dimethylethyl amine, Me 2 NEt); and
(ii) at least one nitrate (—ONO 2 ) group
Typical examples of second component molecules in this example take the form Me 2 N-Et-ONO 2 .
In this embodiment, the second component is linked to the first tetracycline component by a Mannich base attachment through a linker L to the amide group of the first tetracycline component, forming a compound with general structure:
in which Tc is the first tetracycline component, and L is a methylene linker, which can be unsubstituted (—CH 2 —) or substituted with a methyl, ethyl or propyl group (—CHMe-, —CHEt- or CHPr—).
In a preferred sixth embodiment of the first aspect, the second component comprises:
(i) an aza-diethyl molecule (diethyl amine, EtNHEt); and
(ii) at least one nitric oxide releasing or NO mimetic.
Typical examples of second components in this embodiment take the form EtHN-Et-N(O) n , wherein n=1 to 3. Preferably n=3.
In this embodiment, the second component is linked to the first tetracycline component by a Mannich base attachment through a linker L to the amide group of the first tetracycline component, forming a compound with general structure:
in which Tc is the first tetracycline component, and L is a methylene linker, which can be unsubstituted (—CH 2 —) or substituted with a methyl, ethyl or propyl group (—CHMe-, —CHEt- or CHPr—). The linker substituent depends on the aldehyde used in the Mannich base reaction.
In a preferred seventh embodiment of the first aspect, the second component comprises an aza-diethyl molecule (diethyl amine, EtNHEt or diethyl methylamine EtNMeEt) and two nitrate groups, wherein one nitrate group (—ONO 2 ) is attached to each ethyl group. Typical examples of second components in this example take the form HN-(Et-ONO 2 ) 2 . Accordingly, in such embodiments, the second component capable of releasing nitric oxide (NO) having the at least one nitric oxide donor group is N,N-di-ethylnitrate amine.
In this embodiment, the second component is linked to the first tetracycline component by a Mannich base attachment through a linker L to the amide group of the first tetracycline component, forming a compound with general structure:
in which Tc is the first tetracycline component, and L is a methylene linker, which can be unsubstituted (—CH 2 —) or substituted with a methyl, ethyl or propyl group (—CHMe-, —CHEt- or CHPr—). The substituent depends on the aldehyde used in the Mannich base reaction.
In a preferred eight embodiment of the first aspect, the second component comprises:
(i) an aza-pentyl molecule (pentyl amine, pentyl-NH 2 ) or an aza-cyclo-pentyl molecule; and
(ii) at least one at least one nitrate (—ONO 2 ) group.
Typical examples of second components in this example take the form H 2 N-pentyl-ONO 2 or H 2 N-cyclopentyl-ONO 2 . The second component is covalently bonded or linked to the first tetracycline component through the Mannich base attachment described above.
In a preferred ninth embodiment of the first aspect of the invention, the second component comprises a heterocyclic amine, which can be substituted or unsubstituted. Suitably, the nitric oxide releasing group or the NO mimetic can be linked to the heterocyclic amine at the 2, 3, or 4 positions. Preferably, the heterocyclic amine may be selected from piperidine, piperazine or pyrrolidine. The heterocyclic amine may be substituted with a direct —ONO 2 group or a linker-ONO 2 , wherein the linker is a C 1 -C 5 alkyl group or more preferably a C 1 -C 2 alkyl group.
In a preferred tenth embodiment of the first aspect of the invention, the second component comprises:
(i) a piperidine molecule; and
(ii) at least one at least one nitrate (—ONO 2 ) group.
Examples of the second component include:
In this embodiment, the second component is linked to the first tetracycline component by a Mannich base attachment through a linker L to the amide group of the first tetracycline component, forming a compound with general structure:
in which, Tc is the first tetracycline component, and L is a methylene linker, which can be unsubstituted (—CH 2 —) or substituted with a methyl, ethyl or propyl group (—CHMe-, —CHEt- or CHPr—).
In a preferred eleventh embodiment, the second component comprises a combination of:
(i) a piperidine molecule; and
(ii) at least one at least one alkyl-nitrate (R—ONO 2 ) group, in which R is a C 1 -C 5 alkylene group. More preferably R is a C 1 to C 2 alkylene group. Most preferably, the R group is a methylene (—CH 2 —) group. The skilled person will appreciate that the alkyl nitrate group may be substituted at the 2, 3 or 4 position of the piperidine ring. Preferably, the at least one alkyl nitrate group (-alkyl-ONO 2 ) is at the 3 position of the ring.
In this embodiment, the second component is linked to the first tetracycline component by a Mannich base attachment through a linker L to the amide group of the first tetracycline component, forming a compound with general structure:
in which Tc is the first tetracycline component, L is a methylene linker, which can be unsubstituted (—CH 2 —) or substituted with a methyl, ethyl or propyl group (—CHMe-, —CHEt- or CHPr—), and R is a C 1 -C 5 alkylene group. More preferably R is C 1 to C 2 alkylene group. Most preferably, R is methylene.
In a preferred twelfth embodiment, the second component comprises:
(i) a piperidine molecule; and
(ii) at least one at least one —CH 2 ONO 2 group
Suitably, the methyl-nitrate groups can be linked at the 2, 3, or 4 ring positions. Position 3 is the most preferred position. Typical examples of second component molecules in this example include:
In this embodiment, the second component is linked to the first tetracycline component by a Mannich base attachment through a linker L to the amide group of the first tetracycline component, forming compound with general structure:
in which, Tc is the first tetracycline component, L is a methylene linker, which can be unsubstituted (—CH 2 —) or substituted with a methyl, ethyl or propyl group (—CHMe-, —CHEt- or CHPr—).
In a preferred thirteenth embodiment, the second component is a nitrate anion. The nitrate anion is involved in at least one ionic or electrostatic interaction with the tetracycline component. In an example of this embodiment, the second component may be metal nitrate salt. Preferably, the nitrate salt is silver nitrate. Silver nitrate forms a nitrate ionic salt with the tetracycline (TC + NO 3 − ). Typically, a nitrate salt can be formed by reaction of the TC hydrochloride with AgNO 3 , for example.
The preferred compounds of the invention may be selected from:
wherein linker L is a methylene (—CH 2 —), or methylene substituted with a methyl, ethyl or propyl group (—CHMe-, —CHEt- or CHPr—), R is a C 1 -C 5 alkylene group.
In a preferred fourteenth embodiment of the first aspect of the invention, the second component may comprise arginine. Preferably, the second component molecule is L-arginine. L-arginine is a substrate for nitric oxide synthase (NOS) and its metabolites include nitric oxide (NO). Suitably, the L-arginine may be linked to the first tetracycline component through a linker group or molecule as described above.
In a preferred fifteenth embodiment of the first aspect of the invention, the compound may be selected from the group consisting of:
6-deoxy-5-oxytetracycline nitrate salt; doxycycline-5-nitrate
doxycycline-12a-nitrate;
minocycline-12a-nitrate;
amido-N-[3-methylnitratepiperidinomethy]-α-6-deoxy-5-oxytetracycline;
amido-N—[N,N-diethylnitrate-aminomethyl]-α-6-deoxy-5-oxytetracycline (amido-N—[bis-(β-nitrooxyethyl)aminomethyl]-α-6-deoxy-5-oxytetracycline)
amido-N-[(3-nitrooxyethyl)aminomethyl]-α-6-deoxy-5-oxytetracycline
amido-N-[3-(nitrooxymethyl)piperidinomethyl]-α-6-deoxy-5-oxytetracycline
amido-N-[3-(nitrooxymethyl)piperidinomethyl]-α-6-deoxy-5-oxytetracycline
amido-N-[4-(nitrooxymethyl)piperidinomethyl]-α-6-deoxy-5-oxytetracycline
amido-N-[4-nitrooxypiperidinomethyl]-α-6-deoxy-5-oxytetracycline
amido-N-[4-nitrooxypiperidinomethyl]-tetracycline
amido-N—[bis-(β-nitrooxyethyl)methylaminomethyl]-α-6-deoxy-5-oxytetracycline
amido-N—[bis-(β-nitrooxyethyl)methylaminomethyl]-α-6-deoxy-5-oxytetracycline
amido-N—[bis-(β-nitrooxyethyl)ethylaminomethyl]-tetracycline
amido-N-[(β-nitrooxyethyl)aminomethyl]-tetracycline
amido-N-[4-(nitrooxymethyl)piperidinomethyl]-tetracycline
amido-N-[3-(nitrooxymethyl)piperidinomethyl]-tetracycline
In the second aspect of the invention, the combination of the invention may be provided as an admixture of the first and second components of the invention. An admixture means a mixture the components where they are not chemically bonded or associated together on a molecular level. Preferably, in this aspect, at least one of the first tetracycline components described above may be mixed with at least one of the second components examples described above to form an admixture.
In the third aspect of the invention, the combination of the invention may be provided in the form of two or more separate compositions of at least one tetracycline and at least one second component capable of releasing NO or otherwise mimicking the effect of NO in vivo, for administration to a patient to provide the desired therapeutic effect achieved by the admixtures or compound of the invention.
Examples of the second components of the invention include aza-alkyl, aza-alkenyl, or aza-alkynyl groups which are substituted with at least one NO releasing group, as defined above. Preferably, the NO releasing group is a nitrate group. Preferably, the nitrated aza-alkyl, comprises a C 1 to C 5 alkyl, more preferably, a C 1 to C 2 alkyl group. Preferably, the nitrated aza-alkenyl comprises a C 1 to C 5 alkenyl, more preferably a C 1 to C 2 alkenyl group. Preferably, the nitrated aza-alkynyl comprises a C 1 to C 5 alkynl, more preferably a C 1 to C 2 alkynl group. Examples of the second component include H 2 N—R—N(O) n , in which R is a C 1 -C 5 alkyl, alkenyl or alkenyl, more preferably a C 1 -C 2 alkyl alkyl, alkenyl or alkenyl group. The nitric oxide donor group in this example is preferably —ONO 2 . Typical examples of second component molecules are H 2 N-Et-ONO 2 , HN-(Et-ONO 2 ) 2 , MeNH-Et-ONO 2 , Me 2 N-Et-ONO 2 , H 2 N-pentyl-ONO 2 or H 2 N-cyclopentyl-ONO 2 . Further examples of second components include:
Suitably, the second component may be metal nitrate salt. Preferably, the nitrate salt is silver nitrate. Alternatively, the second component molecule may be L-arginine. Clinically used nitric oxide mimetic or donor groups which may be used as second components within the various aspect of the invention and include isosorbide dinitrate, isosorbide 2- and 5-mononitrate, erithrityl tetranitrate, penterithrityl tetranitrate, nicorandil, sinitrodil, glyceryl trinitrate. These clinically used nitrates are particularly preferred in the admixtures aspect of the invention.
According to a fourth aspect of the present invention, there is provided a method of preparing an admixture comprising the step of:
(i) mixing together a first tetracycline component, and
(ii) a second component capable of releasing nitric oxide (NO) or capable of otherwise mincking NO in vivo.
According to a fifth aspect of the present invention, there is provided a method of preparing a compound of the invention, the method comprising the step of:
(i) reacting together a first tetracycline component, and
(ii) a second component capable of releasing nitric oxide (NO) or acting as an NO mimetic,
such that the second component becomes ionically or covalently bonded to the first component, or linked thereto, by means of a linker atom or molecule. In other words, the first tetracycline component becomes associated or linked with the molecule that is capable of releasing nitric oxide (NO) or mimicking its effects.
Preferably, the method comprises reacting a second component compound having at least one functional group comprising N(O) n , wherein n is from 1 to 3, with a first tetracycline component, such that the tetracycline component becomes associated or linked with the compound having at least one functional group comprising N(O) n . It will be appreciated that the second component is capable of releasing nitric oxide (NO).
The skilled person will appreciate that the second component that is capable of releasing nitric oxide (NO) may be involved in at least one type of chemical interaction with the first tetracycline component either directly through covalent bonding or through electrostatic interactions, or indirectly through a linker, such as a chemical functional group or molecule.
In a preferred embodiment, the second component reacts with the first tetracycline component to form a Mannich base link with the tetracycline primary amide. It will be appreciated that this reaction occurs under conditions allowing Mannich base formation. Accordingly, in preferred embodiment, the reaction of the first and second components of the compound of the invention occurs in the presence of an aldehyde. Preferably, the aldehyde is formaldehyde. More preferably still, the aldehyde is paraformaldehyde, which, in the Mannich base attachments results in insertion of a methylene group between the first and second components.
In a preferred embodiment of the method of preparing the compound of the invention, the second component molecule is provided in solution. Suitably, the second component is provided in solution with an alcohol. Preferably, the second component is provided in a secondary alcohol, for example, isopropyl alcohol.
The second component is provided in solution with a secondary alcohol by heating to a temperature of 65-85° C., preferably 75° C. The second component provided in solution with a secondary alcohol is then reacted with the first component at a temperature of 30-50° C., preferably 40° C.
Suitably, the first tetracycline component is provided in solution with an alcohol, an ether or a nitrile. Preferably, the alcohol may be selected from methanol, isopropyl alcohol, or a mixture thereof. Preferably, the ether is a polar ether, for example, tetrahydrofuran (THF). Preferably, the nitrile is acetonitrile.
It will be appreciated that the first tetracycline (TC) component and the second component of the compound of the invention can be any of the tetracylines or second component molecules described herein. However, in a preferred embodiment, the tetracycline component is doxycycline. The preferred second component molecule is N,N-di-ethylnitrate amine.
The solution of the tetracycline component and the solution of the second component are mixed to start the reaction. Preferably, the mixture of the tetracycline and the second component proceeds under constant stirring. Suitably, the reaction is conducted at a temperature of 20-50° C. Preferably, the reaction is conducted at a temperature of 20° C. Alternatively, the reaction is conducted at a temperature of 40° C. The reactants may be stir to facilitate reaction for from about 0.5 to about 18 hours. Preferable, the reaction is conducted for at least 0.5 hour. Alternatively, the reaction is conducted for at least 2 hours. Further alternatively, the reaction is conducted for at least 16 hours. The skilled person will appreciate the time necessary for completion of reaction will depend on the nature of the specific tetracycline component, the second component, their solubilities in the solvents of choice.
In a preferred embodiment, the method of preparing a compound according to the first aspect of the present invention comprises the step of reacting a nitrate-containing group with tetracycline, optionally in the presence of an aldehyde forming a Mannich base with the tetracycline primary amide.
Preferably, the aldehyde is formaldehyde. Further preferably, the aldehyde is paraformaldehyde.
Alternatively, the at least one nitrate-containing group comprises a metal nitrate. Optionally, the at least one nitrate-containing group comprises silver nitrate.
According to a sixth aspect of the present invention, there is provided a pharmaceutical composition comprising a combination of a:
a first tetracycline (TC) component; and
a second component capable of releasing nitric oxide (NO);
wherein the second component is combined with the first tetracycline component.
The term “combined” is intended to cover embodiments wherein (i) the first and second components are associated together through an interaction of the types described below to form a compound comprising both tetracycline and component capable of releasing nitric oxide (NO), and (ii) the tetracycline component and the component capable of releasing nitric oxide (NO) are provided in the form of an admixture of both components, for example, in a single dosage unit; and (iii) the tetracycline component and the component capable of releasing nitric oxide (NO) are provided in the form of two or more separate dosage units for substantially simultaneously administration to a patient.
Accordingly, in a preferred embodiment, the pharmaceutical composition comprises an admixture of the first tetracycline (TC) component; and the second component capable of releasing nitric oxide (NO). In a particularly preferred embodiment, the pharmaceutical composition comprises a compound of the invention.
According to a seventh aspect of the present invention, there is provided a method of treating a disease or condition by administering a therapeutically effective amount of the combination of the invention, wherein the combination comprises:
a first tetracycline (TC) component; and
a second component capable of releasing nitric oxide (NO);
wherein the second component is combined with the first tetracycline component.
Suitably, the method of treating a disease or condition comprises administering a therapeutically effective amount of the combination of the invention to a patient in need thereof. The combination may be administered by providing the patient with a therapeutically effective amount of the compounds described herein. Alternatively, the combination may be administered by providing the patient with a therapeutically effective amount of an admixture of the first tetracycline component and the second component capable of releasing nitric oxide (NO). Alternatively still, the combination may be administered by providing the patient with a therapeutically effective amount of the first and second components by co-administering the tetracycline and the second component capable of releasing nitric oxide (NO), as part of a suitable dosage regimen.
Accordingly, the combinations, the compound or the pharmaceutical compositions of the invention may be used in the medical field. More suitably, the combinations or the compounds of the invention or the pharmaceutical compositions comprising the combination or the compound of the invention can be used in the medical field. The combination, the compound or the pharmaceutical composition of the invention may be used as a medicament or may be used in the manufacture of a medicament for the treatment of, alleviation of, and/or prevention of a disease. In a particularly preferred embodiment, the combination, the compound or the pharmaceutical composition of the invention may be used in the treatment or prevention of inflammatory and/or cardiovascular diseases selected from the group consisting of: myocardial interstitial disease, cardiac fibrosis, heart failure such as heart failure with diastolic heart failure (DHF), heart failure with preserved ejection fraction (HFpEF), congestive heart failure (CHF), asymptomatic left ventricular diastolic dysfunction (ALVDD), coronary atherosclerosis (inflammation effects), cancers (through effects on tumor angiogenesis, tumor growth and metastasis) and diabetes (inflammation effects), inflammatory bowel disease, chronic prostatitis, infections, pulmonary inflammation, osteomyelitis, renal disease, gout, arthritis and shock.
With regard to the admixtures combination aspect of the invention. Admixture of doxycycline and nitrate A (diethanolamine dinitrate), in particular, can be used to treat invasive bladder cancer, chronic prostatitis, acute pyelpnephritis, non-Hodgkins lymphoma, pulmonary infections and osteomyelitis through the effect on IL8. Whereas, an admixture of doxycycline and nitrate A (Diethanolamine dinitrate), in particular, can be used to treat inflammatory bowel disease through effects on IL4. Furthermore, admixtures of doxycycline and nitrate A (Diethanolamine dinitrate) can be used to treat fever, anemia, cryopyrinopathies (hereditary periodic fever syndromes), gout and pseudogout, Septic shock (IL-1β). Alternatively, admixtures of doxycycline and nitrate B (Nitroxymethyl piperidine) can be used to treat fever, anemia, cryopyrinopathies (hereditary periodic fever syndromes), gout and pseudogout, Septic shock (IL-1β). However, admixtures of doxycycline and nitrate A (Diethanolamine dinitrate) are preferred in treating these particular conditions.
With regard to use of the compounds of the invention, preferably, the disease is a cardiovascular disease, such as heart failure. In a particularly preferred embodiment, the combination, the compound or the pharmaceutical composition of the invention is used in treatment or prevention of heart failure caused by or associated with diastolic dysfunction.
In a preferred embodiment, the combinations, the compounds or the pharmaceutical compositions of the invention may be used in the treatment of cancer. Suitably, the cancer may be at least one of the group consisting of: bone metastasis, breast cancer, pancreatic cancer, lung cancer, bladder cancer, colorectal cancer, ovarian cancer, prostate cancer, gallbladder cancer or cancerous brain tumors. Suitably, the cancer is breast or colorectal cancer. The combinations and compounds described herein may be used in conjunction with other drug actives or therapeutic agents known to the skilled person. The other therapeutic agent can provide additive or synergistic value relative to the administration of the combination or the compound of the invention alone, and may be selected from lipid-lowering agents that reduce blood levels of cholesterol and trigylcerides, agents that normalize blood pressure, agents, such as aspirin or platelet ADP receptor antatoginist (e.g., clopidogrel and ticlopidine), that prevent activation of platelets and decrease vascular inflammation, and pleotrophic agents such as peroxisome proliferator activated receptor (PPAR) agonists, with broad-ranging metabolic effects that reduce inflammation, promote insulin sensitization, improve vascular function, and correct lipid abnormalities. Further advantages may arises from combination with another therapeutic agent for cardiovascular disease. Examples of such agents include, but are not limited to an anti-inflammatory agent, an antithrombotic agent, an anti-platelet agent, a fibrinolytic agent, a lipid reducing agent, a direct thrombin inhibitor, a glycoprotein IIb/IIIa receptor inhibitor, an agent that binds to cellular adhesion molecules and inhibits the ability of white blood cells to attach to such molecules, a calcium channel blocker, a beta-adrenergic receptor blocker, a cyclooxygenase-2 inhibitor, an angiotensin system inhibitor, and/or combinations thereof. Antiinflammatory agents include immunosuppressants, TNF inhibitors, corticosteroids, non-steroidal anti-inflammatory drugs (NSAIDs), disease-modifying anti-rheumatic drugs (DMARDS), and the like. Exemplary antiinflammatory agents include, for example, prednisone; methylprenisoione (Medrol®), triamcinolone, methotrexate (Rheumatrex®, Trexall®), hydroxychloroquine (Plaquenil®), sulfasalzine (Azulfidine®), leflunomide (Arava®), etanercept (Enbrel®), infliximab (Remicade®), adalimumab (Humira®), rituximab (Rituxan®), abatacept (Orencia®), interleukin-1, anakinra (Kineret™), ibuprofen, ketoprofen, fenoprofen, naproxen, aspirin, acetominophen, indomethacin, sulindac, meloxicam, piroxicam, tenoxicam, lornoxicam, ketorolac, etodolac, mefenamic acid, meclofenamic acid, flufenamic acid, tolfenamic acid, diclofenac, oxaprozin, apazone, nimesulide, nabumetone, tenidap, etanercept, tolmetin, phenylbutazone, oxyphenbutazone, diflunisal, salsalate, olsalazine or sulfasalazine. The additional therapeutic may be a chemotherapeutic drugs or anti-proliferative agent selected from alkylating agents, antimetabolites, anthracyclines, plant alkaloids, topoisomerase inhibitors, or other antitumour agents, monoclonal antibodies, tyrosine kinase inhibitors, hormones. Exemplary anti-proliferative agents include vinca alkaloids (e.g. vinblastine), the anthracyclines (e.g. adriamycin), the epipodophyllotoxins (e.g. etoposide), antibiotics (e.g. actinomycin D and gramicidin D), antimicrotubule drugs (e.g. colchicine), protein synthesis inhibitors (e.g. puromycin), toxic peptides (e.g. valinomycin), topoisomerase I inhibitors (e.g. topotecan), DNA intercalators (e.g. ethidium bromide), anti-mitotics, vinca alkaloids (e.g. vinblastine, vincristine, vindesine and vinorelbine), epothilones (e.g. epothilone A, epothilone B and discodermolide), nocodazole, colchicine, colchicine derivatives, allocolchicine, Halichondrin B, dolstatin 10, maytansine, rhizoxin, thiocolchicine, trityl cysterin, estramustine, nocodazole, platinum-based agents (e.g. cisplatin, paraplatin, carboplatin, but not the subject platinum-based chemotherapeutic agents as defined herein), camptothecin, 9-nitrocamptothecin (e.g. Orethecin, rubitecan), 9-aminocamptothecin (IDEC-13′), exatecan (e.g. DX-8951f), lurtotecan (GI-147211 C), BAY 38-3441, the homocamptothecins such as diflomotecan (BN-80915) and BN-80927, topotecan (Hycamptin), NB-506, J107088, pyrazolo[1,5-a]indole derivatives, such as GS-5, lamellarin D, irinotecan (Camptosar, CPT-11), and antibodies, such as 1 D1 0, Hu1D10, 1 D09C3, 1C7277, 305D3, rituximab, 4D5, Mab225, C225, Daclizumab (Zenapax), Antegren, CDP 870, CMB-401, MDX-33, MDX-220, MDX-477, CEA-CIDE, AHM, Vitaxin, 3622W94, Therex, 5G1.1, IDEC-131, HU-901, Mylotarg, Zamyl (SMART M195), MDX-210, Humicade, LymphoCIDE, ABX-EGF, 17-1A, Epratuzumab, Cetuximab (Erbitux), Pertuzumab (Omnitarg, 2C4), R3, CDP860, Bevacizumab (Avastin), tositumomab (Bexxar), Ibritumomab tiuxetan (Zevalin), M195, 1D10, Hu1D10 (Remitogen, apolizumab), Danton/DN1924, an “HD” antibody such as HD4 or HD8, CAMPATH-1 and CAMPATH-1H or other variants, fragments, conjugates, derivatives and modifications thereof, or other equivalent compositions with improved or optimized properties.
For example, it is known in the art that doxycycline with zoledronic acid is useful in breast cancer treatment. Adriamycine and 1-beta-D-arabinofuranosykl cytoside combinations are useful in delay of tumor relapse. Combination with cyclophosphamide may also be useful in chemotherapy.
In a eighth aspect of the invention, the combinations or the compounds described herein may be used in a screening method to identify further compounds having benefits in the disease states mentioned above. In a ninth aspect, the combinations or the compounds described herein may be used in determining the suitable of the combination and/or the compounds of the invention for the treatment the disease states mentioned herein.
Further Definitions For the purposes of this specification, in the case of a polyatomic molecule represented by text, a single bond extending between any two atoms is represented by a solid dashed line (—), a double bond extending between any two atoms is represented by a double solid dashed line (═), and a triple bond extending between any two atoms is represented by a triple solid dashed line (≡), unless otherwise stated. By “short chain” is meant a polyatomic molecule comprising at least one carbon atom. Optionally, the polyatomic molecule comprises 1-6 carbon atoms. Further optionally, the polyatomic molecule comprises 1-3 carbon atoms. By the term “linear” is meant a molecule comprising at least two atoms, any of which can be the same or different, wherein each atom of the molecule is bonded to an adjacent atom in a substantially straight series. Each atom can be bonded to an adjacent carbon atom by a single-, double-, triple, or higher order-bond. By the term “branched” is meant a molecule comprising at least three atoms, any of which can be the same or different, bonded in a substantially straight series, wherein the molecule further comprises at least one other atom, which is not bonded to either of the terminal atoms of the substantially straight series. Each atom can be bonded to an adjacent atom by a single-, double-, triple-, or higher order-bond. By “tetracycline” it is meant, the compound (4S,4aS,5aS,6S,12aS)-4-(dimethylamino)-3,6,10,12,12a-pentahydroxy-6-methyl-1,11-dioxo-4,4a,5,5a-tetrahydrotetracene-2-carboxamide. By “minocycline” it is meant, the compound (4S,4aS,5aR,12aS)-4,7-bis(dimethylamino)-3,10,12,12a-tetrahydroxy-1,11-dioxo-4a,5,5a,6-tetrahydro-4H-tetracene-2-carboxamide. By “doxycycline” is meant the compound (4S,4aR,5S,5aR,6R,12aS)-4-(dimethylamino)-3,5,10,12,12a-pentahydroxy-6-methyl-1,11-dioxo-1,4,4a,5,5a,6,11,12a-octahydrotetracene-2-carboxamide. By “oxytetracycline” it is meant, the compound (4S,4aR,5S,5aR,6S,12aS)-4-(dimethylamino)-3,5,6,10,12,12a-hexahydroxy-6-methyl-1,11-dioxo-4,4a,5,5a-tetrahydrotetracene-). In a further aspect, there is provided a combination, compound, composition or use substantially as described herein with reference to the accompanying figures and examples. There is provided a compound comprising a tetracycline, and at least one functional group comprising N(O)n associated with the tetracycline; wherein n is an integer selected from 1-3. Optionally, n is 1. Further optionally, the at least one functional group comprises NO. Still further optionally, the at least one functional group comprises a nitroso group (—N═O). Alternatively, the at least one functional group comprises NO and is selected from a diazeniumdiolate molecule; a NONOate molecule (R 1 R 2 N—(NO—)—N═O; wherein R 1 and R 2 are each independently selected from alkyl groups); and a thionitrite molecule (—SNO). Alternatively, n is 2. Optionally, the at least one functional group comprises NO 2 . Further optionally, the at least one functional group comprises a nitro group (—NO 2 ). Alternatively, the at least one functional group comprises a nitrosooxy (—ONO) group. Further alternatively, the at least one functional group comprises NO 2 and is selected from arginine. Optionally, the at least one functional group is L-arginine, and optionally acts as a substrate for nitric oxide synthase. Further alternatively, n is 3. Optionally, the at least one functional group comprises NO3. Further optionally, the at least one functional group comprises a nitrate group (—ONO 2 ), for example, a nitrate ester, optionally a nitrate ester of an alcohol. Still further optionally, the at least one functional group comprises a nitrate group (—ONO2), for example, a nitrate ester of an alkyl alcohol. Alternatively, the at least one functional group comprises a nitrate group (—ONO2), for example, a conjugate base of nitric acid (nitrate ion). By “associated with” is meant involving at least one chemical interaction. Optionally, the at least one functional group comprising N(O)n is involved in at least one chemical interaction with the tetracycline. Further optionally, the at least one functional group comprising N(O)n involves at least one electrostatic interaction with the tetracycline. Optionally, the at least one functional group comprising N(O)n forms at least one chemical bond with the tetracycline. Further optionally, the at least one functional group comprising N(O)n is a nitrate ester, which forms at least one chemical bond with the tetracycline. Optionally or additionally, the at least one functional group comprising N(O)n forms at least one chemical bond with the tetracycline via a linker molecule. Further optionally, the at least one functional group comprising N(O)n forms at least one chemical bond with the tetracycline via a linker molecule, wherein the at least one functional group comprising N(O)n is attached as a Mannich base to the tetracycline, optionally to the primary amide of the tetracycline. Optionally, the chemical bond is an ionic bond, wherein the interaction between the at least one functional group comprising N(O)n and the tetracycline is an interaction between oppositely charged atoms (or ions). Optionally, the oppositely charged atoms (or ions) are respectively located on or at the tetracycline and the at least one functional group comprising N(O)n. Preferably, the at least one functional group comprising N(O)n is selected from arginine and nitrate ion (ONO3-). Alternatively, the at least one chemical bond is a covalent bond between the at least one functional group comprising N(O)n and the tetracyline. Optionally, the electrons are respectively located on or at each of the at least one functional group comprising N(O)n and the tetracycline. Further optionally, the electrons are common (shared) electrons of the at least one functional group comprising N(O)n and the tetracycline, forming a covalent bond therebetween. Preferably, the compound, or the at least one functional group, is capable of releasing a molecule comprising N(O)n; wherein n is an integer selected from 1-3. Optionally, the compound, or the at least one functional group, is capable of releasing a molecule comprising NO (nitric oxide). Alternatively, the compound, or the at least one functional group, is capable of releasing NO2 (nitrogen dioxide). Further alternatively, the compound, or the at least one functional group, is capable of releasing NO3 (nitrate). By “capable of releasing a molecule” is meant dissociation of a molecule from the compound, such that the molecule is no longer associated with the tetracycline. Nitric oxide is a gaseous molecule that is unsuitable for oral administration. There are several pharmacologically relevant nitric-donor groups than are known to release nitric oxide in response to conditions found in the human body after administration. Exemplary nitric-donor groups are described in “Nitric Oxide Donors: For Pharmaceutical and Biological Applications”; Peng George Wang, Tingwei Bill Cai, Naoyuki Taniguchi, Wiley (2005), which is incorporated herein by reference. Optionally, the tetracycline is doxycycline. By “doxycycline” is meant the compound (4S,4aR,5S,5aR,6R,12aS)-4-(dimethylamino)-3,5,10,12,12a-pentahydroxy-6-methyl-1,11-dioxo-1,4,4a,5,5a,6,11,12a-octahydrotetracene-2-carboxamide. Optionally, the at least one functional group comprising N(O)n comprises: (a) a short-chain a short chain aza-alkyl, aza-alkenyl, or aza-alkynyl molecule, which can be linear, branched, or cyclic, and which can be substituted or unsubstituted; and (b) at least one group comprising N(O) n , wherein n is an integer selected from 1-3, hereinafter referred to as a nitric-oxide donor group. Optionally, the at least one nitric oxide donor group comprises (a) a short-chain a short chain aza-alkyl molecule, which can be linear, branched or cyclic, and which can be substituted or unsubstituted; and (b) at least one at least one nitric oxide donor group. Optionally, the at least one nitric oxide donor-group comprises an amine, which can be linear, branched or cyclic, and which can be substituted or unsubstituted. Further optionally, the at least one nitric oxide donor group comprises a secondary amine, which can be linear, branched or cyclic, and which can be substituted or unsubstituted. Optionally, the at least one nitric oxide donor group comprises an aza-ethyl molecule (ethyl amine) and at least one at least one nitrate group. Further optionally, the at least one nitric oxide donor group comprises an aza-diethyl molecule (diethyl amine) and at least one at least one nitric oxide donor group. Preferably, the at least one nitric oxide donor group is a nitrate-ester containing group. Optionally, the at least one nitric oxide donor group comprises an aza-diethyl molecule (diethyl amine), wherein one nitrate group is attached to each ethyl group. Preferably, the at least one nitric oxide donor group is N,N-di-ethylnitrate amine. Optionally, the at least one nitric oxide donor group comprises a heterocyclic amine, which can be substituted or unsubstituted. Optionally, the at least one nitric oxide donor group comprises an aza-pentyl molecule and at least one at least one nitrate group. Further optionally, the at least one nitric oxide donor group comprises an aza-cyclo-pentyl molecule and at least one at least one nitrate group. Still further optionally, the at least one nitric oxide donor group comprises a piperidine molecule and at least one at least one nitrate group. Optionally, the at least one nitric oxide donor group comprises a piperidine molecule and at least one at least one alkyl-nitrate group. Further optionally, the at least one nitric oxide donor group comprises a piperidine molecule and at least one at least one methyl-nitrate group. Optionally, the at least one nitric oxide donor group comprises a piperidine molecule and at least one at least one alkyl-nitrate group. Further optionally, the at least one nitric oxide donor group comprises a piperidine molecule and at least one at least one methyl-nitrate group. Optionally, the at least one nitrate group, optionally the at least one alkyl-nitrate group, is attached to a carbon atom of the heterocyclic amine, optionally a carbon atom of the piperidine molecule. Further optionally, the at least one nitrate group, optionally the at least one alkyl-nitrate group, is attached to the carbon atom at position 3 of the heterocyclic amine, optionally the carbon atom at position 3 of the piperidine molecule. Optionally, the compound is amido-N—[N,N-diethylnitrate-aminomethyl]-α-6-deoxy-5-oxytetracycline. Alternatively, the compound is amido-N-[3-methylnitratepiperidinomethy]-α-6-deoxy-5-oxytetracycline. Further alternatively, the compound is 6-deoxy-5-oxytetracycline nitrate salt.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the present invention will be described, with reference to the accompanying drawings, in which
FIG. 1 is a graph depicting MMP-9 activity in response to PMA, 150 □M of doxycycline, 450 □M of nitro amine and 150 □M of MJ3-53 (Manich base dinitrate);
FIG. 2 is a graph depicting MMP-2 activity in response to PMA, 150 □M of doxycycline, 450 □M of nitro amine and 150 □M of MJ3-53 (Manich base dinitrate); and
FIG. 3 is a graph depicting MMP-9 expression in patients with varying degrees of DHF.
FIG. 4 demonstrates the effect of SI1003, SI1004, SI1005 and doxycycline on MMP-9 activity in PMA stimulated breast cancer cells (NC=negative control).
FIG. 5 demonstrates the effect of SI1003, SI1004, SI1005 and doxycycline on pro-MMP-2 activity in PMA stimulated breast cancer cells (NC=negative control).
FIG. 6 demonstrates the effect of SI1003, SI1004, SI1005 and doxycycline on MMP-2 activity in PMA stimulated breast cancer cells (NC=negative control).
FIG. 7 demonstrates inhibition of MMP-2 and MMP-9 activity in response to SI1005 (MJ-169).
FIG. 8 demonstrates inhibition of MMP-2 and MMP-9 activity in response to SI1004 (MJ170).
FIG. 9 demonstrates the change in plasma MMP-9 levels from baseline to 72 hours following the administration of doxycycline hyclate (Group 1), SI1004 (Group 2) and SI1005 (Group 3) to groups of 6 cynomolgus monkeys
FIG. 10 . Effect of Doxycycline, SI1004 and SI1005 on colon cancer cell invasiveness (NC=negative control; PC=positive control).
FIG. 11A . Impact of doxycycline hyclate (Doxy) and SI1004 on MMP-9 mRNA in TNFα treated human cardiac fibroblasts (n=3 per group). Shaded bar is 0.1% DMSO+TNFα; striped bars are 0.1% DMSO+Doxycycline hyclate (concentrations shown) and solid black bars represent 0.1% DMSO+SI1004 (concentrations shown). All values represent mean and SEM. I represents p<0.01 vs TNFα, **p<0.01 vs. Doxy. All bars were significantly elevated vs. serum free controls.
FIG. 11B . Impact of doxycycline hyclate (Doxy) and SI1004 on proliferation of human cardiac fibroblasts (n=3 per group) following 72 hours of serum starvation (clear bars) and subsequent exposure to 72 hours of 2% fetal calf serum (FCS) with 0.1% DMSO (shaded bars), 0.1% DMSO+Doxycycline hyclate (concentrations shown, striped bars) and 0.1% DMSO+SI1004 (concentrations shown, black solid bars). All values represent mean and SEM. □ represents p<0.05 vs. 2% FCS, □□p<0.01 vs 2% FCS, *p<0.05 vs. Doxy, **p<0.01 vs. Doxy. All bars except SI1004 150 μM were significantly elevated vs. serum free controls.
FIG. 12 . Impact of doxycycline hyclate (striped bars) and SI1004 (solid bars) on [A] total MMP-9 and [B] total MMP-2 AUC in serum from cynomologus monkeys following daily orogastric gavage dosing for 72 hours (n=6). Doses used were 1.6 mg/kg doxycycline hyclate at time 0 and 4.8 mg/kg doxycycline hyclate at 24 and 48 hours, or the molar equivalents of SI1004.
FIG. 13 : Admixtures may be more effective than doxycycline in attenuating fibroblast proliferation, but not as effective as SI1004. In the following study Doxy and nitrate A are significantly better than Doxy at inhibiting Cardiac Fibroblast Proliferation (p=0.011) at 150 uM However, Doxy and nitrate B are not (p=NS) at same concentration. SI1004 is significantly more effective than doxycycline, Doxy and nitrate A, Doxy and nitrate B at 150 uM (all p<0.01).
FIG. 14 . Admixtures reduce some inflammatory markers similarly to Doxy, e.g. IL-8. In the following study, Doxy and nitrate A can significantly reduce IL-8 levels in TNFalpha stimulated PBMCs at 150 uM (p<0.01). Doxy alone and Doxy and nitrate B also reduce IL-8 levels compared to controls (p<0.05).
FIG. 15 . Admixtures reduce some inflammatory markers more effectively than doxycycline, e.g. IL-1beta. In the following study, Doxy and nitrate A can significantly reduce IL-1 beta levels in TNFalpha stimulated PBMCs (p<0.05). Doxy and nitrate B reduce IL-1 beta levels, but not significantly (p=NS).
FIG. 16 . Admixtures reduce some inflammatory markers more effectively than doxycycline, e.g. IL-4. In the following study, Doxy and nitrate A can significantly reduce IL-4 levels in TNFalpha stimulated PBMCs. Doxy and nitrate B admixtures reduce IL-4 levels, but not significantly (p=NS). IL-4 is reduced significantly more (p<0.01) by Doxy and nitrate A than either Doxy or Doxy and nitrate B. In this study, we see that not all NO donors provide similar efficacy.
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will now be exemplified, with reference to the following non-limiting examples.
EXAMPLE 1
Preparation of Nitrate-Containing Group, N,N-Diethylnitrate Amine
All materials were purchased from the Sigma-Aldrich chemical company. With reference to Scheme 1, 1.5 mL fuming nitric acid was dissolved in 10 mL DCM at −15° C. Diethanolamine (0.42 g, 4 mmole) dissolved in DCM (3 mL) was added dropwise over 20 minutes. The reaction mixture was then left stirring for a further 30 minutes before acetic anhydride (2 mL) was added to quench the reaction. The reaction was then left stirring for a further 5 minutes to form a precipitate. The precipitate was filtered washed with cold DCM and dried under vacuum to give N,N-diethylnitrate amine as a white solid.
HRMS ESI+ve C4H9N3O6 [M+H] requires 196.0570, found 196.0574. 1H NMR δ 3.52-3.54 triplet (2×CH2-O), δ 4.81-4.83 multiplet (2×CH2-N).
EXAMPLE 2
Preparation of Nitrate-Containing Group, 3-Methylnitrate Piperidine
With reference to Scheme 2, 1.5 mL fuming nitric acid was dissolved in 10 mL DCM at −15° C. 3-hydroxymethyl piperidine (0.46 g, 4 mmole) dissolved in DCM (3 mL) was added dropwise over 20 minutes. The reaction mixture was then left stirring for a further 30 minutes before acetic anhydride (2 mL) was added to quench the reaction. The reaction was then left stirring for a further 5 minutes.
The pH of the reaction mixture was then adjusted to 14 with 7M NaOH. The reaction mixture was then extracted with DCM (3×2o mL) and the combined organic extracts were washed with brine, dried over Na2SO4, filtered and solvent removed in vacuo to give 4-methyl nitrate piperidine as a pale yellow oil.
HRMS ESI+ve C6H12N2O3 [M+H]+ requires: 161.0921; found: 161.0923. 1H NMR: δ 3.62 multiplet (CH2-ONO2), δ 3.35-3.20 multiplet (C2, C6 CH2), 2.19 multiplet (C3CH) 2.11-1.90 multiplet (C5CH2).
EXAMPLE 3
Preparation of Amido-N—[N,N-Diethylnitrate-Aminomethyl]-α-6-Deoxy-5-Oxytetracycline
Referring to Scheme 3, N,N-di-ethylnitrate amine (0.095 g, 0.487 mmole; as prepared in Example 1) and paraformaldehyde (0.016 g, 0.487 mmole) were suspended in 10 mL isopropyl alcohol and heated to 75° C. under an inert atmosphere for 30 minutes until a clear solution was obtained. The reaction mixture was then cooled to 40° C. and doxycycline hyclate (0.250 g, 0.487 mmole), dissolved in a mixture of 5 mL isopropyl alcohol and 0.5 mL methanol, was added dropwise over 5 minutes. The reaction mixture was stirred at 40° C. for a further two hours. Upon completion of the reaction, the mixture was cooled and solvent removed to give amido-N—[N,N-diethylnitrate-aminomethyl]-α-6-deoxy-5-oxytetracycline as a pale yellow solid.
MS ESI-ve C27H33N5O14 [M−H]− requires 650.1951, found 650.1938. 1H NMR: δ 4.05 ppm singlet (Mannich methylene), δ 7.5, 6.95 ppm triplets and 7.85 ppm doublet (three phenyl protons) 2.9 ppm & 2.8 ppm singlets (dimethylamino, C4), δ 9.6 ppm singlet (amide), 3.52-3.54, triplet and 4.81-4.83, multiplet (diethyl amino nitrate).
or alternative synthesis:
Amido-N-[Bis-(β-Nitrooxyethyl)Aminomethyl]-α-6-Deoxy-5-Oxytetracycline
Diethanolamine-dinitrate (234 mg, 1.2 mM, 1.2 eq), doxycycline free base (414 mg, 1 mM, 1.0 eq) and paraformaldehyde (60 mg, 2 mM, 2 eq) were dissolved in anhydrous tetrahydrofuran (10 ml) and heated to refluxing for 2 h under nitrogen environment. Then another portion paraformaldehyde (60 mg, 2 mM, 2 eq) were added into the reaction mixture. After refluxing for another 2 h, the reaction mixture was cooled to room temperature and filtered. The filtrates were collected and the solvent was removed. The resulting solids were dried under vacuum to afford the title compound as a brown microcrystalline solid (162 mg, 25%). m p.=101-104° C. Calculated for C 27 H 32 N 5 O 14 =650.2024; found (M−H) − =650.1965. 1 H NMR (400 MHz, d 6 -DMSO) δ 15.2 (1H, s), 11.5 (1H, s), 9.64 (1H, s), 9.1 (1H, s), 7.54 (1H, t, J=8), 6.94 (1H, d, J=8), 6.88 (1H, d, J=8), 5.4 (1H, s), 4.8 (4H, t, J=5), 4.65 (1H, dd, J=12, 7) 4.44 (1H, dd, J=12, 7) 4.17 (1H, s) 3.46-3.44 (5H, m) 2.73-2.65 (7H, m) 2.50-2.52 (1H, m) 1.47 (3H, d, J=7). 13 C NMR (400 MHz, d 6 -DMSO) ppm: 192.5, 171.6, 161.1, 147.8, 136.6, 115.8, 115.6, 115.5, 107.2, 73.2, 71.6, 68.8, 68.6, 68.0, 67.0, 62.0, 49.8, 45.2, 44.2, 41.3, 31.2; 15.8.
IR (KBr) v (cm −1 ): 3382; 2969; 1648; 1383; 1283; 849.
EXAMPLE 4
Preparation of Amido-N-[3-Methylnitratepiperidinomethy]-α-6-Deoxy-5-Oxytetracycline
Referring to Scheme 4, to 6-deoxy-5-oxytetracycline hyclate (0.461 g, 0.899 mmole) in anhydrous THF (10 mL) was added 3-methylnitrate piperidine (as prepared in Example 2) and 0.1 mL 37% formaldehyde solution. The reaction mixture was stirred at 40° C. for 16 hours. The reaction mixture was then cooled and solvent removed under reduced pressure to give amido-N-[4-methylnitratepiperidinomethy]-α-6-deoxy-5-oxytetracycline as a pale yellow solid. MS APCI C29H36N4O11 [M+NH4] requires 616.2831 found 616.2944. 1 H NMR: δ 4.05 ppm singlet (Mannich methylene), δ 7.5, 6.95 ppm triplets and 7.85 ppm doublet (three phenyl protons) 2.9 ppm & 2.8 ppm singlets (dimethylamino, C4), δ 9.6 ppm singlet (amide), δ 3.62 multiplet (CH 2 —ONO 2 ), δ 3.35-3.20 multiplet (C2, C6CH2), 2.19 multiplet (C3CH) 2.11-1.90 multiplet (C5CH 2 )
or alternative synthesis:
Amido-N-[3-(Nitrooxymethyl)Piperidinomethyl]-α-6-Deoxy-5-Oxytetracycline
3-Nitrooxymethyl piperidine (192 mg, 1.2 mM, 1.2 eq), doxycycline free base (414 mg, 1 mM, 1.0 eq) and paraformaldehyde (60 mg, 2 mM, 2 eq) were dissolved in anhydrous tetrahydrofuran (10 ml) and heated to refluxing for 2 h under nitrogen environment. Then another portion of paraformaldehyde (60 mg, 2 mM, 2 eq) was added into the reaction mixture. After refluxing for another 2 h, the reaction mixture was cooled to room temperature and filtered. The filtrates were collected and the solvent was removed. The resulting solids were dried under vacuum to afford the title compound as a pale yellow microcrystalline solid (153 mg, 25%). Calculated for C 29 H 35 N 4 O 11 =615.2308; found (M−H) − =615.2291. 1 H NMR (400 MHz, d 6 -DMSO) δ 15.3 (1H, s) 11.6 (1H, s) 10.12 (1H, s) 9.64 (1H, s) 7.54 (1H, t, J=8) 6.94 (1H, d, J=8) 6.88 (1H, d, J=8) 5.72 (1H, s) 4.65 (1H, dd, J=12.7) 4.45-4.30 (3H, m) 4.07 (1H, s) 3.22-3.35 (2H, m) 2.98-2.89 (2H, m) 2.80-2.65 (8H, m) 2.15-1.96 (2H, m) 1.89-1.75 (2H, m) 1.52-1.4 (4H, m).
EXAMPLE 5
Preparation of 6-Deoxy-5-Oxytetracycline Nitrate Salt
With reference to Scheme 5, a nitrate salt is prepared by adding silver nitrate (0.50 g, 2.96 mmole) to a solution of doxycycline hydrochloride (1.52 g, 2.96 mmole) in acetonitrile (20 mL). The solution is then stirred at room temperature for 30 minutes.
After 30 minutes, a white precipitate of silver chloride was removed by filtration to leave a pale yellow solution. This solution was added dropwise to cold diethyl ether (100 mL) to form a pale yellow precipitate that was filtered, washed with cold diethyl ether, and dried under vacuum.
HRMS ESI C22H24N2O8 [M]+ requires 445.1605, found 445.1602.
EXAMPLE 6
Docycycline-5-Nitrate
A solution of doxycyline (414 mg, 1 mmol) in 5 ml THF was added to the solution of Cu(NO 3 ) 2 (750 mg, 3 mmol) in 15 ml of acetic anhydride, which had been reacted for 2 h at room temperature. After reacted at −10° C. for 3 hour, the reaction mixture was filtered. The solvent of the filtrate was removed and dried under vacuum to give an amber solid (215, 44%). Calculated for C 22 H 24 N 3 O 10 =490.1456; found (M+H) + =490.1469.
EXAMPLE 7
4-Nitrooxymethyl piperidine (192 mg, 1.2 mM, 1.2 eq), doxycycline free base (414 mg, 1 mM, 1.0 eq) and paraformaldehyde (60 mg, 2 mM, 2 eq) were dissolved in anhydrous tetrahydrofuran (10 ml) and heated to refluxing for 2 h under nitrogen environment. Then another portion of paraformaldehyde (60 mg, 2 mM, 2 eq) was added into the reaction mixture. After refluxing for another 2 h, the reaction mixture was cooled to room temperature and filtered. The filtrates were collected and the solvent was removed. The resulting solids were dried under vacuum to afford the title compound as a pale yellow microcrystalline solid (128 mg, 21%). m p.=130-132° C. Calculated for C 29 H 35 N 4 O 11 =615.2308; found (M−H) − =615.2277. 1 H NMR (400 MHz, d 6 -DMSO) δ 15.3 (1H, s) 11.6 (1H, s) 9.64 (1H, s) 9.1 (1H, s) 7.54 (1H, t, J=8) 6.94 (1H, d, J=8) 6.88 (1H, d, J=8) 5.72 (1H, s) 4.65 (1H, dd, J=12, 7) 4.45-4.30 (3H, m) 4.07 (1H, s) 3.22-3.35 (2H, m) 2.98-2.89 (2H, m) 2.73-2.65 (7H, m) 2.50 (1H, m) 2.15-1.96 (2H, m) 1.89-1.75 (2H, m) 1.52-1.4 (5H, m). 13 C NMR (400 MHz, d 6 -DMSO) ppm: 192.5, 171.6, 161.1, 147.8, 136.7, 115.8, 115.6, 115.5, 107.1, 76.4, 68.9, 68.2, 66.6, 50.7, 45.3, 41.6, 38.4, 31.2, 26.6, 15.8.
IR (KBr) v (cm −1 ): 3401; 29769; 1634; 1383; 1279; 867.
EXAMPLE 8
Amido-N-[4-nitrooxypiperidinomethyl]-α-6-deoxy-5-oxytetracycline
4-nitrooxypiperidine (175 mg, 1.2 mM, 1.2 eq), doxycycline free base (414 mg, 1 mM, 1.0 eq) and paraformaldehyde (60 mg, 2 mM, 2 eq) were dissolved in anhydrous tetrahydrofuran (10 ml) and heated to refluxing for 2 h under nitrogen environment. Then another portion of paraformaldehyde (60 mg, 2 mM, 2 eq) was added into the reaction mixture.
After refluxing for another 2 h, the reaction mixture was cooled to room temperature and filtered. The filtrates were collected and the solvent was removed. The resulting solids were dried under vacuum to afford the title compound as a pale yellow microcrystalline solid (192 mg, 32%). Calculated for C 28 H 33 N 4 O 11 =601.2151; found (M−H) − =601.2152. 1 H NMR (400 MHz, d 6 -DMSO) δ 15.3 (1H, s) 11.6 (1H, s) 9.64 (1H, s) 7.54 (1H, t, J=8) 6.94 (1H, d, J=8) 6.88 (1H, d, J=8) 5.72 (1H, s) 5.27-5.30 (m, 1H) 4.65 (1H, dd, J=12, 7) 4.43 (1H, dd, J=12, 7) 4.07 (1H, s) 3.22-3.25 (4H, m) 2.73- 2.65 (7H, m) 2.50 (1H, m), 1.88-1.91 (2H, m) 1.47 (3H, d, J=7).
EXAMPLE 9
Amido-N-[3-(nitrooxymethyl)piperidinomethyl]-α-6-deoxy-5-oxytetracycline
3-Nitrooxymethyl piperidine (192 mg, 1.2 mM, 1.2 eq), doxycycline free base (414 mg, 1 mM, 1.0 eq) and paraformaldehyde (60 mg, 2 mM, 2 eq) were dissolved in anhydrous tetrahydrofuran (10 ml) and heated to refluxing for 2 h under nitrogen environment. Then another portion of paraformaldehyde (60 mg, 2 mM, 2 eq) was added into the reaction mixture. After refluxing for another 2 h, the reaction mixture was cooled to room temperature and filtered. The filtrates were collected and the solvent was removed. The resulting solids were dried under vacuum to afford the title compound as a pale yellow microcrystalline solid (171 mg, 28%). Calculated for C 29 H 35 N 4 O 11 =615.2308; found (M−H) − =615.2305.
EXAMPLE 10
Amido-N-[(β-nitrooxyethyl)aminomethyl]-α-6-deoxy-5-oxytetracycline
1-Methylaminoethyl nitrate (200 mg, 1.88 mM, 1.2 eq), doxycycline free base (700 mg, 1.55 mM, 1.0 eq) and paraformaldehyde (93 mg, 3.1 mM, 2 eq) were dissolved in anhydrous tetrahydrofuran (10 ml) and heated to refluxing for 2 h under nitrogen environment. Then another portion paraformaldehyde (93 mg, 3.1 mM, 2 eq) were added into the reaction mixture. After refluxing for another 2 h, the reaction mixture was cooled to room temperature and filtered. The filtrates were collected and the solvent was removed. The resulting solids were dried under vacuum to afford the title compound as a pale yellow microcrystalline solid (261 mg, 30%). Calculated for C 26 H 31 N 4 O 11 =575.1995; found (M−H) − =575.2032. 1 H NMR (400 MHz, d 6 -DMSO) δ 15.2 (1H, s), 11.5 (1H, s), 9.64 (1H, s), 9.64 (1H, s), 7.54 (1H, t, J=8), 6.94 (1H, d, J=8), 6.88 (1H, d, J=8), 5.4 (1H, s), 4.8 (2H, t, J=5), 4.65 (1H, dd, J=12, 7) 4.44 (1H, dd, J=12, 7) 4.17 (1H, s) 3.46-3.44 (3H, m) 2.73-2.65 (7H, m) 2.50-2.52 (1H, m) 1.47 (3H, d, J=7).
EXAMPLE 11
Amido-N-[4-nitrooxypiperidinomethyl]-tetracycline
4-nitrooxypiperidine (175 mg, 1.2 mM, 1.2 eq), tetracycline free base (414 mg, 1 mM, 1.0 eq) and paraformaldehyde (60 mg, 2 mM, 2 eq) were dissolved in anhydrous tetrahydrofuran (10 ml) and heated to refluxing for 2 h under nitrogen environment. Then another portion of paraformaldehyde (60 mg, 2 mM, 2 eq) was added into the reaction mixture. After refluxing for another 2 h, the reaction mixture was cooled to room temperature and filtered. The filtrates were collected and the solvent was removed. The resulting solids were dried under vacuum to afford the title compound as a brown microcrystalline solid (216 mg, 36%). Calculated for C 28 H 33 N 4 O 11 =601.2151; found (M−H) − =601.2147. 1 H NMR (400 MHz, d 6 -DMSO) δ 15.3 (1H, s) 11.6 (1H, s) 9.64 (1H, s) 9.64 (1H, s) 7.54 (1H, t, J=8) 7.1 (1H, d, J=8) 6.93 (1H, d, J=8) 5.27-5.30 (m, 1H) 5.10 (1H, s) 4.65 (1H, dd, J=12, 7) 4.43 (1H, dd, J=12, 7) 4.07 (1H, s) 3.22-3.25 (4H, m) 2.65-2.73 (7H, m) 2.50 (1H, m), 2.04-2.13 (2H, m) 1.88-1.91 (2H, m) 1.53 (3H, s).
EXAMPLE 12
Amido-N-[bis-(β-nitrooxyethyl)aminoethyl]-α-6-deoxy-5-oxytetracycline
Diethanolamine dinitrate (195 mg, 1 mmol, 1 eq) doxycycline free base (450 mg, 1 mmol, 1 eq) and acetaldehyde (110 uL, 88 mg, 2 eq) were dissolved in anhydrous tetrahydrofuran (10 ml) and heated to reflux for 2 hours under nitrogen environment. A further 2 equivalents of acetaldehyde were added to the reaction mixture and the reaction continued for a further 2 h. The reaction mixture was then cooled to room temperature and filtered. THF was removed from the filtrate via rotary evaporation and the resultant residue was dried under vacuum to give an amber solid. (235 mg, 35%) 1 H NMR (400 MHz, d 6 -DMSO) δ 15.2 (1H, s), 11.5 (1H, s), 9.64 (1H, s), 7.54 (1H, t, J=8), 6.94 (1H, d, J=8), 6.88 (1H, d, J=8), 5.4 (1H, s), 4.57 (4H, t, J=5), 4.44, 1H, dd, J=12, 7) 4.17 (1H, s) 3.46-3.44 (5H, m) 2.73-2.65 (7H, m) 2.50-2.52 (1H, m) 1.78 (3H, d, J=7) 1.47 (3H, d, J=7).
EXAMPLE 13 & 14
Doxycycline -12a-nitrate; and minocycline-12a-nitrate; both of which may be prepared by mild nitration under acidic conditions. In vitro pharmacological evaluation
Cells (CaCo2 cells) were seeded onto a 12-well plate, and allowed to grow to 70% confluence. When cells were 70% confluent, the media on the cells were replaced with serum-free media. Cells were then treated with increasing concentrations of test compound (50 □M-250 □M), for 3 hours in a 37° C. incubator. After 3 hours, 10 □M PMA (Phorbol 12-myristate 13-acetate) was added to the cells to induce production of MMPs. Cells were incubated for 24 hours in a 37° C. incubator. After 24 hours, the media from each well were collected and centrifuged at max speed for 5 minutes to pellet any cellular debris, and the media was removed to fresh microfuge tubes. A Bradford assay was conducted to determine the protein concentration of each media sample. An equal protein concentration of each media sample was loaded onto a zymography gel, which was run for 150V/2 hours. Following this, the zymography gel was washed three times for 20 minutes in 2.5% Triton X Buffer and was washed 2 times in zymography buffer before being incubated in zymography buffer at 37° C. for 48-72 hours to allow any MMP9 and MMP2 present to digest the gelatinase in the gel. Following this, the gels were stained in coomassie blue stain for 3 hours with gentle rocking and destained for 1 hour, resulting in a blue gel with clear bands where MMP's that were present had digested through the gelatine in the zymography gels. Densitometry analysis was performed to quantitate the amount of MMPs present relative to the PMA positive control sample. Referring to FIG. 1 , addition of 150 uM of doxycycline did not affect MMP-9 levels. N,N-diethylnitrate amine, at equimolar concentrations to the Mannich base dinitrate (amido-N—[N,N-diethylnitrate-aminomethyl]-α-6-deoxy-5-oxytetracycline) on its own, inhibited MMP-9 by over 50%. However, the combination of doxycycline with the nitrate amine amido-N—[N,N-diethylnitrate-aminomethyl]-α-6-deoxy-5-oxytetracycline] (MJ3-53) suppressed MMP-9 activity by approximately 60%. Referring to FIG. 2 , it can be seen that MMP-2 activity was significantly inhibited by doxycycline (80%), and the combination with amido-N—[N,N-diethylnitrate-aminomethyl]-α-6-deoxy-5-oxytetracycline reduced MMP-2 activity by about 40%. These data demonstrate that a compound of the present invention is capable of significantly altering MMP expression, and finds utility in treating or preventing heart failure, optionally heart failure caused by or associated with diastolic dysfunction; where MMP-9 levels are three times higher in the advanced stages compared with mild DHF. In DHF, MMP2 is 40 to 50% higher and MMP9 is 200-300% higher in heart failure patients than in asymptomatic hypertensive patients. In the present example, surprisingly, the amido-N—[N,N-diethylnitrate-aminomethyl]-α-6-deoxy-5-oxytetracycline inhibits MMP9 more than by the constituent doxycycline and N,N-diethylnitrate amine. Moreover, the pattern of MMP 2 and MMP9 inhibition may be more beneficial than doxycycline alone, which, in these examples, did not reduce MMP9.
In-vitro/in-vivo Effects of Doxycycline and SI1004
The purpose of this study was to evaluate the in-vitro/in-vivo effects of doxycycline and SI1004, a novel NO-releasing analogue of doxycycline which could be applied to the treatment of disorders associated with elevated MMP-9 including ALVDD and HFpEF.
Methods
Direct Inhibition of Recombinant MMP-2 and MMP-9 with SI1004 and Doxycycline.
Nitrocycline, SI1004, a dinitroxyethyl conjugate with doxycycline was prepared in-house using conventional chemical approaches and characterised by 1 H, 13 C NMR, High Resolution Mass Spectroscopy and High Performance Liquid Chromatography. Doxycycline hyclate was obtained from Sigma-Aldrich Ireland. In order to determine the relative direct inhibitory effects of SI1004 and doxycycline on MMP-2 and MMP-9 we used human recombinant enzymes (R&D Systems, Ireland) with the synthetic broad-spectrum fluorogenic substrate (7-methoxycoumarin-4-yl)-acetyl-pro-Leu-Gly-Leu-(3-(2,4-dinitrophenyl)-L-2,3-diaminopropionyl)-Ala-Arg-NH 2 (R&D Systems, UK) as previously described (34).
Effects of SI1004 and Doxycycline on Human Ventricular Cardiac Fibroblast (HCF) proliferation and on TNF-α treated HCF MMP-2 and MMP-9 transcription.
The impact of SI1004 and doxycycline on MMP-2 and MMP-9 transcription was evaluated in primary HCFs purchased from ScienCell Research Laboratories. Cells were cultured in Dulbecco's modified eagles medium (DMEM) (Gibco), supplemented with 10% Fetal Calf Serum (FCS) (Gibco) and penicillin-streptomycin antibiotics (Gibco) in a 5% CO 2 humidified incubator kept at 37° C. To investigate effects of test articles on cell proliferation, HCF cells were serum starved for 72 hours and then treated with either 75 or 150 μM of test article in DMSO in 2% FCS for a further 72 hours. Cell viability was measured using the CellTitre-Glo Luminescent Cell Viability Assay (Promega) which measures ATP as an indicator of the number of metabolically active cells. To investigate the relative effects of doxycycline and SI1004 on TNFα treated HCF transcription of MMP-2 and MMP-9, cells were treated with 10 ng/mL human recombinant TNFα (R&D Systems) for 72 hours in the presence of 75 μM or 150 μM of test article in DMSO. RNA was isolated using a NucleoSpin RNA II Kit (Macherey-Nagel). First strand cDNA synthesis was carried out using SuperScript II RT (Invitrogen). QPCR primers were designed so that one of each primer pair was exon/exon boundary spanning to ensure only mature mRNA was amplified. The sequences of the gene-specific primers used are as follows; MMP-2, 5′-CACGTGACAAGCCCATGGGGCCCC-3′ (forward), 5′-GCAGCCTAGCCAGTCGGATTTGATG-3′ (reverse); MMP-9,5′-GTGCTGGGCTGCTGCTTTGCTG-3′ (forward), 5′-GTCGCCCTCAAAGGTTTGGAAT-3′ (reverse). QPCR reactions were normalized by amplifying the same cDNA with GAPDH primers, 5′-ACAGTCAGCCGCATCTTCTT-3′ (forward), 5′-ACGACCAAATCCGTTGACTC-3′ (reverse). QPCR was performed using Platinum SYBR Green qPCRSuperMix-UDG (Invitrogen). Amplification and detection were carried out using the Mx3000P System (Stratagene). The PCR cycling program consisted of 40 three-step cycles of 15 seconds/95° C., 30 seconds/TA and 30 seconds/72° C. Each sample was amplified in duplicate. In order to confirm signal specificity, a melting program was carried out after the PCR cycles were completed. The samples were quantified by comparison with a standard calibration curve created at the same time and the data was normalized by an internal control (glyceraldehyde 3-phosphate dehydrogenase).
Effects of SI1004 and Doxycycline on MMPs, TIMP-1 and Inflammatory Markers in Human Peripheral Blood mononuclear cells (PBMC) stimulated with TNF-α.
To further explore the relative impact of SI1004 and doxycycline on inflammatory cells (PBMC), venous blood (30 mL) was collected from three healthy volunteers (age 30-37) in 10 mL S-Monovette tubes with anti-coagulant 9NC (Sarstedt). The blood was mixed with an equal volume of D-PBS (Gibco) and two volumes of the mixture were layered over one volume of Lymphoprep gradient solution (Axis-Shield). PBMC were isolated by centrifugation at 400 g for 40 minutes. PBMC were collected from the plasma/lymphoprep interface and washed three times in D-PBS/0.1% BSA/2 mM EDTA. PBMC were suspended at 1×10 6 cells/mL in pre-warmed RPMI 1640/10% FCS/2 mM L-glutamine/100 μg/mL penicillin G/100 μg/mL Streptomycin (all from Gibco). Cells (0.2×10 6 ) were plated at a concentration of 1.0×10 6 in 96-well plates in duplicates, stimulated with 10 ng/mL TNFα (R&D Systems) with/without doxycycline hyclate or SI1004 (at 75 and 150 μM) and incubated for 24 hours at 37° C. On the following day, all samples were centrifuged and supernatants were stored at −80° C. for immunoassays. Percent PBMC viability following drug treatment was determined using the CellTiter-Glo Luminescent Cell Viability Assay (Promega) according to the manufacturer instructions. The cytokine profile of the cell supernatants was analysed using an ultra-sensitive immunoassay with electrochemiluminescence detection according to the manufacturer's instructions (Meso Scale Discovery). MMP secretion was also quantified using multiplex immunoassays with electrochemiluminescence detection as instructed by the manufacturer (MMP2/10 Duplex and MMP1/3/9 Triplex assays—MesoScale Discovery). Single-plex assays were used for monocyte chemotactic protein (MCP)-1 (Meso Scale Discovery). Plates were analyzed using a Meso Scale Discovery Sector Imager 2400 instrument. Secreted TIMP-1 was quantified using a standard ELISA (Amersham, GE Healthcare). TH1/TH2 10-plex assay was used to study IFNγ, IL-1β, IL-2, IL-4, IL-5, IL-8, IL-10, IL-12p70, IL-13, and TNFα. The sensitivity (lowest level of detection) of the assays was 0.12 ng/mL and 0.1 ng/mL for MMP-2 and MMP-9, respectively. The coefficient of variation of the lower limit of the standard curve for MMP-2 and MMP-9 was 4.9% and 1.2% respectively. Plates were analyzed using a Meso Scale Discovery Sector Imager 2400 instrument.
Relative Effects of SI1004 and Doxycycline on Total MMP-2 and MMP-9 Levels on Acute and Repeated Oral administration over three days with dose titration following day one in non-human primates (NHP).
A total of 12 purpose bred, purpose bred, naïve, non-human primates (cynomolgus monkeys, 2.9-4 kg) were sourced and randomly allocated in a parallel group design (n=6 per group) to receive SI1004, SI1005 and equimolar doses of doxycycline daily (1.6 mg/kg doxycycline hyclate equivalents, on day 1 and 4.8 mg/kg doxycycline equivalents on days 2 and 3) by oral gavage in aqueous vehicle over a 3 day period. Studies were carried out consecutively in two contract research organization sites (Charles River, Sparks, Nev., US and Charles River, Shanghai, China). The study protocol was approved by PCS-SHG Institutional Animal Care and Use Committee before conduct. During the study, care and use of animals was conducted in accordance with the guidelines of the USA National Research Council and the Canadian Council on Animal Care. The cynomolgus monkey was chosen for this study in order to maximize the likelihood of identifying responses that are similar to those that may be expected in humans. Each animal was identified by a cage label and body tattoo and was acclimated to orogastric dosing on at least two occasions prior to the initiation of dosing. The vehicle (1% (w/v) tween 80 and 0.5% (w/v) carboxymethylcellulose in deionized water) or 1.6 mg/kg doxycycline hyclate (0 hours) or 4.8 mg/kg doxycycline hyclate (24, 48 hours) or the molar equivalent(s) of SI1004 or SI1005 were administered using an orogastric tube inserted through the mouth and advanced into the stomach. The animals were temporarily restrained (i.e. manually) for dose administration, and were not sedated. Disposable sterile syringes and orogastric tubes were used for each animal/dose. Each dose was followed by a tap water flush of approximately 5 mL. Blood samples and blood pressure measurements were taken at the following timepoints: pre-dose (0 hours) and at 2, 4, 6, 12, 24, 26, 30, 36, 48, 50, 54, 60 and 72 hours after first administration of test article. We have previously demonstrated an acute phase response in this model to repeated venepuncture (3-6 fold increase in high sensitivity C-reactive protein from baseline at 12 and 24 hours post dose respectively, (both p=0.01 vs baseline), data not shown). Blood (300 μL) for serum preparation was collected intoBD Vacutainer®+Serum SST™ tubes to accelerate clotting 20 minutes prior to centrifugation to allow complete clotting to occur and centrifuged at 1500-2200 rpm at 2-8° C. for 10-15 minutes. Under these conditions blood cells containing MMP, principally neutrophils and platelets, undergo full degranulation. Since artifactual elevation of MMP-9 was an unavoidable feature of repeated venipuncture in our model, it was logical to stimulate full MMP-9 release during sample collection. This provided greater inter-animal reproducibility and a more dynamic analytical range for assessing the relative effects of the test articles. Subsequent MMP-9 values provide an index of total MMP-9 including circulating enzyme, amplified by repeated venipuncture, along with the cellular load released from storage granules during clotting. The latter is influenced by earlier inflammatory signaling, transcription and storage. The serum was transferred to a cryovial and immediately stored at −70° C. until analyzed for MMP-2 and MMP-9 via a Luminex ELISA (total MMP-2 and MMP-9) within 48 hours of collection. The analysis of each time point was repeated within 5 days. Values that differed by more than 15% were repeated. The primary study endpoint was the change in plasma MMP-2 and MMP-9 levels at 72 hours. Secondary endpoints were area under the curve (AUC) values of MMP-2 and MMP-9 over the following periods: 0-24, 0-48 and 0-72 hours. Additional 0.4 mL aliquots were placed in K 2 EDTA tubes and processed to plasma for combined nitrate/nitrate (NO x ) analysis using a modified Greiss assay as previously described (35). Simultaneous blood pressure measurements were made in triplicate using a femur cuff linked to an automated Omron analyzer. Data are presented as mean±standard error of the mean (SEM) for continuous normal variables, median, interquartile range (IQR) with 95% confidence intervals for non-normal continuous variables and frequencies and percents for nominal/categorical variables. Comparisons between doxycycline and SI1004 groups in the NHP study were made on changes over the study period using independent two-sample t-tests for continuous normally distributed data, Mann-Whitney for skewed continuous and chi-squared for categorical data. Within group tests, comparing baseline to 24, 48 and 72 hour values, were conducted using paired sample t-tests and paired sample Wilcoxon tests where appropriate. Analyses were carried out using SPSS V.13 statistical software (Statistical Package for the Social Sciences: SPSS Inc, Chicago, Ill., 2001).
Results
Effects of Doxycycline and SI1004 on Activity of Recombinant Human MMP-2 and MMP-9
Doxycycline and SI1004 had similar direct inhibitory effects on MMP-2 and MMP-9 enzymatic activity. Doxycycline (100 μM) inhibited recombinant human MMP-2 (34.0±3.5%) and MMP-9 (33.3±3.5%) (p<0.05). Similarly SI1004 (100 μM) inhibited MMP-2 and MMP-9 by 29.7±2.1% and 26.6±1.7% respectively (p<0.05). However, there was no direct inhibition of either enzyme by the test articles at 10 μM. These values suggest weak, non-selective inhibition of both gelatinases at enzyme level and are consistent with doxycycline's low binding affinity for the MMPs.
Effects of Doxycycline and SI1004 on Human Cardiac Fibroblasts
In contrast to doxycycline hyclate, SI1004 significantly inhibited TNFα induced upregulation of MMP-9 mRNA (p=0.01, FIG. 1A ). MMP-9 protein levels were below the lower limit of quantification in doxycycline hyclate or SI1004 treated cell supernatants. There were no significant effects of doxycycline hyclate or SI1004 on MMP-2 mRNA expression. Also, unlike doxycycline, SI1004 (75-150 μM) caused significant inhibition of HCF proliferation in 2% FCS following serum starvation for 72 hours, (p=0.02, FIG. 1B ).
Effects of Doxycycline and SI1004 on Markers of Inflammation and Collagen Turnover in Human Peripheral Blood Mononuclear Cells
The effects of doxycycline hyclate and SI1004 on MMPs, TIMP-1, inflammatory cytokines and MCP-1 are presented in Table 1. Both compounds significantly inhibited PBMC supernatant MMP-9, TIMP-1, IFNγ, IL-8, IL-12p70 and MCP-1 (all p<0.05). SI1004 (150 μM) but not doxycycline, inhibited IL-1β production at 150 μM (p=0.03). Doxycycline inhibited TIMP-1 to a greater extent than SI1004 at both concentrations (p<0.05) and doxycycline, but not SI1004, inhibited MMP-3 (p<0.02).
Plasma MMP-2 and MMP-9 Levels Over 72 Hours with Daily Dosing of Doxycycline and SI1004 in Cynomolgus Monkeys
Oral administration of SI1004 caused more effective suppression of total serum MMP-9 protein levels than doxycycline ( FIG. 12A ). Between-group differences were significant by day 2 and remained significant on day 3 in terms of AUC (24-48 and 48-72 hours) and also in terms of MMP-9 change from baseline at 48 and 72 hours (all p<0.05). Total MMP-2 levels were similar over the 3-day treatment period ( FIG. 12B ). Maximum plasma doxycycline concentration (Cmax) was noted on day 3 of dosing where plasma doxycycline concentration achieved 5.1 μM (base equivalents). SI1004 caused an increase in mean plasma nitrite/nitrate (NOx) over the duration of the dosing period, with peaks at 6 hours post-dosing (i.e. at 6, 30 and 54 hours) consistent with activation of the SI1004 nitrate group and NO release. NOx Cmax (μg/mL) for SI1004 was 12.1±2.2, 47.9±2.2, and 50.4±12.5, on days 1, 2 and 3 respectively (all at 6 hours post dose). Although the mean systolic blood pressure was higher in the doxycycline hyclate group (109.7±7.1 mmHg vs 101±6.3, p<0.01), there was no difference in diastolic blood pressure (58.6±6.0 mmHg vs 56.4±3.8 mmHg, p=NS) and the pattern of NO release was not associated with significant differences in blood pressure (either systolic or diastolic) or heart rate at any time point.
TABLE 1
Impact of doxycycline hyclate and SI1004 on MMPs, TIMP-1, interleukins and MCP-1
protein levels in supernatants of PBMC treated over 24 hours (n = 3).
All values are mean ± SEM (ng/mL)
Doxycycline
Doxycycline
SI1004
SI1004
Control
(150 μM)
(75 μM)
(150 μM)
(75 μM)
No.(%)/Mean ± SD
No.(%)/Mean ± SD
Interleukin-1β
40.8 ± 6.2
30.6 ± 5.0
34.6 ± 5.8
24.6 ± 1.2
27.8 ± 6.6
Interleukin-4
12.0 ± 0.6
9.8 ± 0.8
9.4 ± 1.2
9.6 ± 0.6
10.8 ± 0.2
Interleukin-5
49.8 ± 11.6
31.2 ± 5.8
40.8 ± 9.0
35.6 ± 6.4
35.8 ± 8.4
Interleukin-8
15322 ± 264
6352 ± 1438
8852 ± 2568
8826 ± 1364
10960 ± 484
Interleukin-10
121.2 ± 51.2
92.2 ± 33.8
136.6 ± 74.2
142.0 ± 55.2
125.6 ± 32.2
Interleukin-12p70
19.8 ± 1.0
14.2 ± 2.0
16.2 ± 2.4
15.2 ± 1.0
16.6 ± 1.2
Interleukin-13
106.6 ± 0.6
80.2 ± 3.2
79.6 ± 17.2
89.4 ± 13.2
80.8 ± 24.8
MCP-1
598 ± 338
30.0 ± 8.0
92.0 ± 54.0
40.0 ± 14.0
146 ± 54
Interferon γ
124.4 ± 6.8
86.6 ± 8.8
99.5 ± 15.0
100.2 ± 7.6
102.8 ± 4.8
MMP-1
262 ± 132
134 ± 48
144.0 ± 80.0
171 ± 66.0
208 ± 102
MMP-2
126.0 ± 104.6
96.8 ± 80.6
61.4 ± 54.2
95.4 ± 52
120.4 ± 86.4
MMP-3
11.3 ± 2.8
2.9 ± 0.4
1.5 ± 1.5
9.1 ± 6.1*
8.7 ± 5.2*
MMP-9
29.4 ± 7.6
1.3 ± 0.6
3.4 ± 1.6
8.4 ± 2.1 **
18.4 ± 7.3 *
MMP-10
84.4 ± 25.2
47.6 ± 15.8
36.0 ± 14.0
29.0 ± 14.6
26.6 ± 18.4
TIMP-1
56.0 ± 4.2
6.8 ± 2.4
12.6 ± 1.6
22.0 ± 9.2 *
32.4 ± 9.4 *
All values represent mean and SEM.
represents p < 0.05 vs. TNFα treated controls,
p < 0.01 vs TNFα treated controls,
*p < 0.05 vs. Doxy,
**p < 0.01 vs. Doxy.
Abbreviations:
MCP = monocyte chemotactic protein,
MMP = matrix metalloproteinase,
TIMP = tissue inhibitor of matrix metalloproteinase.
SI1004 and doxycycline have low binding capacity to MMP-2 and MMP-9 enzymes at concentrations achieved in-vivo. Both compounds inhibit TNFα induced MMP-9, TIMP-1, IFNγ, IL-8, IL-12p70 and MCP-1 expression in PBMC. Unlike doxycycline, SI1004 inhibits IL-1β and also TNFα induced MMP-9 mRNA in HCF and HCF proliferation. SI1004 has similar effects on MMP-2 in-vivo and more effectively reduces total plasma MMP-9 (median AUC 4.3 μg/mL.hour, IQR 3.1-5.5) than doxycycline (median AUC 8.7 μg/mL.hour, IQR 7.3-11.3, p<0.05 vs doxycycline) in NHPs.
Conclusions: This study demonstrates that doxycycline and SI1004 are immunemodulatory MMP inhibitors. SI1004 provides more effective inhibition of inducible MMP-9 than doxycycline.
Discussion
HFpEF accounts for 40-60% of all cases of HF and is set to increase with continued high prevalence of ALVDD driven principally by hypertension and diabetes. Experience to date with renin-angiotensin-aldosterone system (RMS) modifying therapies suggests that novel therapeutic approaches are needed. While RMS modifying therapies have shown anti-fibrotic effects, several lines of in-vitro and in-vivo evidence point to co-existing inflammation and ECM remodeling as key drivers of HFpEF pathophysiology. ECM remodeling is regulated by myocardial MMPs and TIMPs which have been elusive pharmacological targets in the clinic. The present study provides a pharmacological and pathophysiological rationale for further evaluation of immunomodulatory, broad-spectrum MMP inhibitor doxycycline and its novel NO-releasing analogue (SI1004) as components of an anti-remodeling strategy in ALVDD and HFpEF. Furthermore, SI1004 reduces transcription of inducible myocardial MMP-9 and total MMP-9 in-vivo more effectively than doxycycline and this may provide efficacy and safety advantages in chronic therapy. Abnormalities in the cardiac interstitium are central to the pathophysiology of ALVDD and HFpEF. These abnormalities include delayed relaxation, impaired left ventricular filling and/or increased stiffness in the myocardium. Myocardial remodeling is characterized by inflammation, fibrosis (increased collagen production, reduced collagen breakdown, alterations in the relative balance of collagen I/III, changes in the biomechanical properties of myocardial collagen) and alterations in other components of the ECM such as fibronectin, laminin and elastin. Modulation of the cardiac interstitium in pressure/volume overload is partially regulated by MMPs and TIMPs and recent human studies have associated serum and tissue myocardial MMP levels with increased arterial stiffness in patients with hypertension, hypertrophic obstructive cardiomyopathy, diastolic dysfunction and HFpEF. Supporting these observations are animal studies showing MMP-9 and its tissue inhibitor, TIMP-1, are associated with the transition from hypertrophy to HF the development of diastolic dysfunction and HFpEF in models of chronic pressure-overload. MMP-2 and MMP-9 knockout mice develop less marked cardiomyocyte hypertrophy and fibrosis following transverse aortic banding and pharmacological MMP inhibition prevents ventricular remodeling and HF in pressure overload states, including HF induced by inflammatory cytokines. However, direct pharmacological inhibition of MMPs has been unsuccessful as a chronic therapy in the clinic. Over 60 MMP-binding inhibitors have been tested, primarily in cancer and heart disease, with consistently disappointing efficacy or unacceptable side-effect profiles. The 24 human MMPs and their TIMPs also contribute to a large array of important physiological processes. Thus, for example, chronic, direct inhibition of collagenases may actually facilitate myocardial fibrosis in pressure overload states. It is important to note that MMP-2 has collagenase activity and activates other collagenases, unlike MMP-9, suggesting it may have role in the attenuation of excess collagen deposition in the myocardium. Conversely, MMP-9 basal activity is normally low but its gene contains binding sites for AP-1, NF-κB, Sp-1, Ets-1 and Egr-1. Global deletion of MMP-9, endows mice with a benign phenotype in the absence of pathophysiological stress. However, following induction of myocardial infarction, MMP-9 knockout mice demonstrate reduced macrophage infiltration, left ventricular dilation and collagen accumulation as well as increased vascularity and perfusion. Taken together, these data indicate that pharmacological attenuation of inducible myocardial MMP-9 and MMP secretion without chronic direct enzyme inhibition could be an effective and/or safer therapeutic approach in patients with ALVDD and HFpEF. Doxycycline is the only therapy licensed for human use as a MMP inhibitor, in the setting of periodontal disease, and is currently under investigation by our group in ALVDD and HFpEF (EudraCT number: 2010-021664-16). As well as direct inhibitory effects on a range of MMPs, doxycycline also inhibits the acute phase MMP-9 release from tertiary granules in neutrophils. The present study suggests that doxycycline has low binding capacity for myocardial MMP at plasma levels achieved in this study and during chronic human dosing (<10 μM) and this may be an advantage in terms of long term safety at conventional doses. Furthermore, the effect of doxycycline and SI004 on IFNγ and IL-12p70 secretion by TNFα stimulated PBMCs suggests a reduced capacity to promote T cell activation. Both agents also suppress IL-8 and MCP-1 secretion from activated PBMCs indicating an ability to inhibit neutrophil and monocyte chemotaxis. These data are in accordance with previous in-vivo evidence of doxycycline suppression of neutrophil and cytotoxic T cell accumulation in the aortic wall of patients undergoing elective aneurysmal repair. Given the emerging importance of inflammation in the early phases of HFpEF and the potentially causal role of MCP-1 in the recruitment of monocytes and initiation of interstitial fibrosis in animal models of pressure overload our data suggest a beneficial anti-inflammatory role for doxycycline and SI004 in ALVDD and HFpEF. The additional effects of NO release on pro-inflammatory stimuli and gelatinase activity may amplify doxycycline's inhibitory effect in the setting of HFpEF. Doxycycline reduces NO and peroxynitrite levels in multiple cell types stimulated with inflammatory cytokines, partly through inducible nitric oxide synthase (iNOS) inhibition. It is also known that intracellular NO formation can suppress IL-1β by inhibiting caspase-1, the IL-1β converting enzyme which may explain the significant reduction of SI1004 on this inflammatory cytokine. NO can also affect the cellular distribution and compartmentalization of MMP-9, decrease MMP-9 mRNA stability and inhibit its transcription via effects on AP-1, NF□B and PEA3 promoter activity. Furthermore, vascular NO is depleted in hypertension and NO has well-known effects on vascular smooth muscle cells, activating guanylate cyclase and increasing the formation of cyclic guanosine monophosphate (cGMP), causing vasorelaxation, reduced pulse wave reflection and reduced central aortic pressure. NO and cGMP releasing substances are associated with an improvement in diastolic relaxation that suggest a beneficial effect in diastolic HF. A final potential advantage of nitrocycline is that while short and long-term use of doxycycline can cause gastro-eosophageal irritation, NO is gastroprotective and NO donor groups can increase the intestinal tolerability and safety of a number of drugs. The present study identifies a number of key differences between SI1004 and its parent molecule. Of potential importance in myocardial remodeling is that SI1004 has superior efficacy on MMP-9 mRNA in TNF□ stimulated HCF. SI1004 may have less inhibitory effects on TIMP-1 and MMP-3 which are associated with the attenuation of myocardial remodeling and increased scar volume after myocardial injury. By processing samples to serum with complete clotting, which causes degranulation of PBMCs and platelets, we obtained an index of total MMP-9 protein in-vivo. SI1004 was strikingly more effective than doxycycline hyclate in the inhibition of MMP-9, consistent with inhibitory effects on MMP-9 RNA and a broader anti-inflammatory profile. These effects may make the nitrocycline approach therapeutically relevant in pathologies where there is a strong inflammatory component associated with elevated MMP-9 levels including ALVDD and HFpEF. In conclusion, ALVDD and HFpEF are diseases driven by inflammation, fibrosis and abnormalities of ECM turnover. This study presents in-vitro and in-vivo evidence of efficacy of doxycycline and SI1004, a novel, NO-releasing tetracycline analogue, as immunomodulatory, MMP inhibitors. SI1004 is a more effective inhibitor of MMP-9 transcription and serum MMP-9 in NHPs, than doxycycline. These agents are considered to be useful in treatment of diseases associated with elevated MMP.
Cancer Applications
As discussed in the background section, Matrix Metalloproteinase (MMP) levels in the plasma are known biomarkers of breast, colorectal, renal, pancreas, bladder and lung cancers (see Table 2).
TABLE 2
Candidate MMP and ADAM Biomarkers of Cancer
(Roy, Yang et al. 2009)
Type of Cancer and MMPs/ADAMs
Detected in Tissue/Body Fluid
Breast
MMP-13
Tissue
MMP-9, TIMP-1
Serum, tissue
MMP-9
Urine, serum, plasma, tissue
ADAM12
Urine
ADAM17
Tissue
MMP-1
Tissue, nipple aspirates
Pancreas
MMP-9
Pancreatic juice, serum
MMP-2
Pancreatic juice, tissue
MMP-7
Tissue, plasma
ADAM9
Tissue
Lung
VMMP-9, TIMP-1
Serum, bronchial lavage
MMP-7
Tissue
MMP-1
Tissue
Bladder
MMP-9
Tissue
MMP-9, MMP-2
Urine
MMP-9
Urine
MMP-9, telomerase
Urine
Colorectal
MMP-2
Tissue, plasma
MMP-9
Tissue
MMP-2, MMP-9
Plasma
MMP-7
Serum
MMP-1
Tissue
MMP-13
Tissue
Ovarian
MMP-9
Tissue
MMP-9, MMP-14
Tissue
MMP-2
Tissue
MMP-2, MMP-9, MMP-14
Tissue
ADAM17
Tissue
Prostate
MMP-2, MMP-9
Plasma, tissue
MMP-2
Tissue
MMP-9
Urine
ADAM8
Tissue
ADAM9
Tissue
Brain
MMP-2
Tissue
MMP-9
Tissue
MMP-2, MMP-9
Tissue, cerebrospinal fluid, urine
MMPs are involved in cancer cell intravasation and extravasation. They effect Extracellular Matrix (ECM) degradation and disrupt cell-cell interactions promoting cell migration. MMP-9 is also involved in endothelial-mesenchymal-transition (EMT) whereby cells acquire migratory characteristics and this is also facilitated by MMP-3 (via interactions with E-cadherin and Rac1b). MMPs modulate growth factors and receptors. MMP-9 modulates vascular endothelial growth factors which promotes tumour growth and angiogenesis. MMP-3 modulates insulin like growth factor binding proteins and basic fibroblast growth factors and is also known to activate MMP-9. MMPs also modulate tumour associated inflammation (e.g. MMP-9 is involved in breast cancer inflammation) via cytokines and their receptors.
Anti Cancer Effect of the Compounds of the Invention
SI1004 (MJ-170, Dinitrate MB) is a more effective MMP-9 inhibitor nitrocycline than SI1005 (MJ-169, Piperidine Mono MB), which has been shown to inhibit MMP-3. Accordingly, it may be able to more selectively reduce MMP-9 protein levels than SI1004. Both SI1004 and SI1005 are more potent MMP-9 inhibitors than conventional doxycycline.
In Vitro Data
Using in vitro breast cancer cell models (HT1080 cells), stimulated with a pro-inflammatory insult (PMA) to stimulate the over-production of MMP-9, we see that doxycycline (Doxy), SI1004 (MJ-170, Dinitrate MB) and SI1005 (MJ-169, Piperidine Mono MB) all reduce MMP-9 production at 100 micromolar concentrations. Using the same in vitro breast cancer cell models for examining MMP-2, we see that PMA reduces pro-MMP-2 and doxycycline (Doxy), SI1004 (MJ-170, Dinitrate MB) and to a lesser extent SI1005 (MJ-169, Piperidine Mono MB) all reduce pro-MMP-2 production at 100 micromolar. However, surprisingly, doxycycline (Doxy) also appears to increase the conversion of available pro-MMP-2 to active MMP-2 ( FIG. 5 ). This, potentially, could be a concern for chronic doxycycline therapy in the treatment of cancer. Advantageously, we do not see the same activation of MMP-2 with nitrocyclines.
Using models of direct enzyme inhibition, it is shown below that SI1004 (MJ-170, Dinitrate MB) and SI1005 (MJ-169, Piperidine Mono MB) are more potent inhibitors of MMP-9 than doxycycline. The 1050 value (μM) of SI1005 (MJ-169, Piperidine Mono MB) for MMP-2 and MMP-9 are 63 (46-84) and 139 (86-223) respectively. The IC 50 value (μM) of SI1004, (MJ-170, Dinitrate MB) for MMP-2 and MMP-9 are 9.4 (8.5-10.4) and 25 (19-32) respectively. These are more potent than doxycycline which has an approximate IC 50 value (μM) for MMP-2 and MMP-9 of 129 and 164 respectively
TABLE 2
IC 50 values for the inhibition of MMP-2 and MMP-9 in
response to SI1004, SI1005 and doxycycline.
SI1004 (MJ-170)
SI1005 (MJ-169)
Doxycycline
MMP-2
9.4 μM
63 μM
129 μM
MMP-9
25 μM
139 μM
164 μM
MMP-8: SI1005 (MJ-169, Piperidine Mono MB) has around 53.8% inhibition at 100 μM and 16.9% inhibition at 10 μM. SI1004 (MJ-170, MJ-170, Dinitrate MB) has around 60.7% inhibition at 100 μM and 26.0% inhibition at 10 μM. Doxycyline has around 42.7% inhibition at 100 μM. MMP-13: SI1005 (MJ-169, Piperidine Mono MB) has around 28.4% inhibition at 100 μM and 6.6% inhibition at 10 μM and SI1004 (MJ-170, MJ-170, Dinitrate MB) has around 74.5% inhibition at 1000 and 46.0% inhibition at 10 μM. Doxycyline has around 54% inhibition at 100 μM. MMP-1: SI1005 (MJ-169, Piperidine Mono MB) has around 22% inhibition at 100 μM and 13% inhibition at 10 μM while SI1004 (MJ-170, MJ-170, Dinitrate MB) has around 63% inhibition at 100 μM and 19% inhibition at 10 μM. Doxycyline has around 12% inhibition at 100 μM.
In Vivo Data
Nitrocycline compounds SI1004 (MJ-170, Dinitrate MB, Group 2), SI1005 (MJ-169, Piperidine Mono MB, Group 3) and doxycycline hyclate control (Doxy Group 1) were administered to cynomolgus monkeys (n=6 per group) as described in the method below. The test articles were administered by oral gavage once daily for three days (Doxycycline hyclate 1.6 mg/day and equimolar doses of the nitrocyclines were administered on Day 1. These doses were equivalent to 100 mg/day of doxycycline base. The dose of doxycycline hyclate was increased to 4.6 mg/kg on the second and third 20 day. Equimolar doses of nitrocyclines were administered. This dose was equivalent to a 300 mg/day dose of doxycycline base). The primary endpoint of this study was the changes in MMP-9 from baseline to 72 hours. In the high dose doxycycline group (Group 1), MMP-9 levels increase. In the SI1004 (Group 2) MMP-9 levels are significantly reduced compared to doxycycline. In the SI1005 (Group 3) MMP-9 levels are significantly reduced compared to doxycycline and SI1004. These data provide proof-of-concept in vivo support for the use of SI1004 and SI1005 as more potent inhibitors of MMP-9 compared to doxycycline. Furthermore, SI1004 and SI1005 are more potent inhibitors of inflammatory cytokines such as IL-1b, IL-4 and IL-8 compared to doxycycline (data not shown). Finally, in order to provide a functional model of tumour cell invasion, the following data show that that at low dose, doxycycline (Doxy) does not reduce colon cancer cell invasiveness, whereas SI1004 (MJ-170, Dinitrate MB) and SI1005 (MJ-169, Piperidine Mono MB) do ( FIG. 10 ). Overall nitrocyclines SI1004 and SI1005 appear to be more potent inhibitors of MMP enzymes and this may be an advantage in the management of cardiovascular disease and cancer. SI1004 appears to be more MMP-9 specific and does not reduce MMP-3 in in vitro inflammatory cell models. Both nitrocyclines SI1004 and SI1005 are more effective immunomodulatory compounds. They do not appear to activate MMP-2, unlike high concentration (100 μM) doxycycline. Finally, they are more effective in reducing tumour cell invasiveness in an in vitro model with human colon cancer cells.
In Vivo, Non-Human Primate Study. Methods
Purpose bred, naïve, non-human primates (cynomolgus monkeys, 2.9-4 kg) were sourced and randomly allocated in a parallel group design (n=6 per group) to receive SI1004, SI1005 and equimolar doses of doxycycline daily (1.6 mg/kg doxycycline hyclate equivalents, on day 1 and 4.8 mg/kg doxycycline equivalents on days 2 and 3) by oral gavage in aqueous vehicle over a 3 day period. Studies were carried out consecutively in two contract research organization sites (Charles River, Sparks, Nev., US and Charles River, Shanghai, China). The study protocol was approved by PCS-SHG Institutional Animal Care and Use Committee before conduct. During the study, care and use of animals was conducted in accordance with the guidelines of the USA National Research Council and the Canadian Council on Animal Care. The cynomolgus monkey was chosen for this study in order to maximize the likelihood of identifying responses that are similar to those that may be expected in humans. Each animal was identified by a cage label and body tattoo and was acclimated to orogastric dosing on at least two occasions prior to the initiation of dosing. The vehicle (1% (w/v) tween 80 and 0.5% (w/v) carboxymethylcellulose in deionized water) or 1.6 mg/kg doxycycline hyclate (0 hours) or 4.8 mg/kg doxycycline hyclate (24, 48 hours) or the molar equivalent(s) of SI1004 or SI1005 were administered using an orogastric tube inserted through the mouth and advanced into the stomach. The animals were temporarily restrained (i.e. manually) for dose administration, and were not sedated. Disposable sterile syringes and orogastric tubes were used for each animal/dose. Each dose was followed by a tap water flush of approximately 5 mL. Blood samples and blood pressure measurements were taken at the following timepoints: pre-dose (0 hours) and at 2, 4, 6, 12, 24, 26, 30, 36, 48, 50, 54, 60 and 72 hours after first administration of test article. Blood (300 μL) for serum preparation was collected intoBD Vacutainer®+Serum SST™ tubes to accelerate clotting 20 minutes prior to centrifugation to allow complete clotting to occur and centrifuged at 1500-2200 rpm at 2-8° C. for 10-15 minutes. Under these conditions blood cells containing MMP, principally neutrophils and platelets, undergo full degranulation. Since artifactual elevation of MMP-9 was an unavoidable feature of repeated venipuncture in our model, it was logical to stimulate full MMP-9 release during sample collection. This provided greater inter-animal reproducibility and a more dynamic analytical range for assessing the relative effects of the test articles. Subsequent MMP-9 values provide an index of total MMP-9 including circulating enzyme, amplified by repeated venipuncture, along with the cellular load released from storage granules during clotting. The latter is influenced by earlier inflammatory signaling, transcription and storage. The serum was transferred to a cryovial and immediately stored at −70° C. until analyzed for MMP-2 and MMP-9 via a Luminex ELISA (total MMP-2 and MMP-9) within 48 hours of collection. The analysis of each time point was repeated within 5 days. Values that differed by more than 15% were repeated. The primary study endpoint was the change in plasma MMP-2 and MMP-9 levels at 72 hours. Secondary endpoints were area under the curve (AUC) values of MMP-2 and MMP-9 over the following periods: 0-24, 0-48 and 0-72 hours.
Data on Admixtures ( FIGS. 13-17 )
Admixtures of tetracyclines and nitric oxide donors have benefits in inflammatory and cardiovascular diseases. In FIG. 13 , Doxy and nitrate A admixture (Diethanolamine dinitrate, the alkyl nitrate component of SI1004) are significantly better than Doxy at inhibiting cardiac fibroblast proliferation (p=0.011) at 150 micromolar. However, Doxy and nitrate B admixture (Nitroxymethyl piperidine) are not (p=NS) at same concentration. The novel nitrocycline, SI1004, is significantly more effective at inhibiting cardiac fibroblast proliferation than doxycycline, Doxy and nitrate A admixture, Doxy and nitrate B admixture at 150 micromolar (all p<0.01). In some cases, inflammatory cytokines are similarly reduced by Doxy and admixtures with NO donors. In FIG. 14 , Doxy and nitrate A admixtures are shown to significantly reduce IL-8 levels in TNFalpha stimulated PBMCs at 150 micromolar (p<0.01). Doxy alone and Doxy and nitrate B admixtures also reduce IL-8 levels compared to controls (p<0.05). However, in some instances, the effects Doxy and nitrate A admixture is more effective than Doxy. In FIG. 15 , Doxy and nitrate A (Diethanolamine dinitrate) admixture can significantly reduce IL-1 beta levels in TNFalpha stimulated PBMCs (p<0.05). Doxy and nitrate B (Nitroxymethyl piperidine) admixture reduce IL-1 beta levels, but not significantly (p=NS). Furthermore, in some instances, the choice of NO donor dramatically alters the anti-inflammatory effects. In FIG. 16 it is shown that IL-4 is reduced significantly more (p<0.01) by Doxy and nitrate A (Diethanolamine dinitrate) admixture than either Doxy or Doxy and nitrate B (Nitroxymethyl piperidine) admixture. IL-4 is implicated in inflammatory bowel disease. IL-8 is implicated in invasive bladder cancer, chronic prostatitis, acute pyelpnephritis, non-Hodgkins lymphoma, pulmonary infections and osteomyelitis. IL-1β is implicated in fever, anemia, cryopyrinopathies (hereditary periodic fever syndromes), gout and pseudogout, Septic shock.
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A combination of: a first tetracycline (TC) component; and a second component capable of releasing nitric oxide (NO) or a nitrate capable of mimicking NO effects in vivo (NO mimetic). The combinations of the invention advantageously act as more effective MMP modulators with selective reductions in circulating MMP-9 levels in-vivo and inhibitory effects on MMP-2 and MMP-9 levels in-vitro. The combinations of the invention also advantageously act as modulators of inflammation mediators. The co-existence of abnormalities of MMP enzymes and inflammation in many diseases make these characteristics advantageous. Therefore, the various combinations of the invention find utility in medical applications where MMPs and/or inflammation is implicated.
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FIELD OF THE INVENTION
[0001] The invention relates to a modular exhaust manifold of a motor vehicle with multiple adjoining single-wall manifold pipe modules, with at least one engine flange, via which multiple inlet connecting pieces of the manifold pipe modules can be connected to a cylinder head of the motor vehicle, wherein at least one manifold pipe module configured as a collector pipe module and having a contact flange is provided, via which manifold pipe module the exhaust manifold can be connected to an exhaust system of the motor vehicle, wherein the respective manifold pipe module has an overlapping contour of a length a that ensures the telescoping of two manifold pipe modules at a time to an insertion depth t for the purpose of coupling, wherein at least two manifold pipe modules are identical in shape.
[0002] The invention further relates to a method for producing a manifold formed from multiple adjoining manifold pipe modules, each of them having at least one joining surface and one inlet connecting piece, wherein, according to the method, the respective manifold pipe module configured as a hinged shell is closed and so connected as to be gas-tight in the region of the joining surface and the engine flange is welded onto the inlet connecting piece.
BACKGROUND OF THE INVENTION
[0003] A cast-part modular exhaust manifold whose various modules are at least partially identical in shape is already known from U.S. Pat. No. 4,288,988 A. If one wants to ensure sufficiently high process reliability, the walls of cast parts will have to be relatively thick.
[0004] A branch socket of an exhaust manifold configured as a hinged shell is known from DE 101 49 381 A1. The sheet metal section is cut and then deep-drawn and trimmed. This is followed by a forming process so that the joining flanges can be welded in a final step. Therefore, multiple branch sockets would be produced as a one-piece component with an increased number of bulges in the deep-drawing process.
[0005] A two-shell modular exhaust manifold whose internal-pipe modules are configured as hydroformed parts is known from DE 103 28 027 A1. The modules can be connected to each other by means of close sliding fits or plug-type connectors (already known from DE 43 39 290 C2) and are welded to each other via the outer shell. The internal pipes and the outer shells can be easily connected by means of the close sliding fits. Concerning the outer shell, the close sliding fits ensure the compensation for production-related tolerances prior to welding so that a weldable cover of the outer shell is provided in any case. The various modules may be provided as elements of a modular system. The manifold formed in this way tapers starting from the first arc module, i.e., the cross-section of the pipe increases continuously. Therefore, however, modules having different shapes, i.e., not being identical in shape, are required for designing a manifold.
[0006] A two-shell modular exhaust manifold whose internal-pipe modules are configured as hydroformed parts is also known from DE 199 23 557 A1. Furthermore, the use of identical components for the internal manifold pipes is described, said parts making the production of a six-cylinder or eight-cylinder exhaust manifold from a four-cylinder exhaust manifold possible.
[0007] JP 9 296 725 A describes a cast-part modular exhaust manifold, wherein the manifold pipe modules to be connected have an overlapping contour configured for telescoping. Said overlapping contour or the additional use of a sliding element makes relative motions between the manifold pipe modules on account of thermal stress or thermal expansion possible. For this purpose, appropriate meander-shaped compensating sleeves or bellows sleeves are provided in the region of the aforementioned overlapping contour, said sleeves ensuring tightness between two interconnected modules on the one hand and compensation between the manifold pipe modules connected thereto on the other hand.
SUMMARY OF THE INVENTION
[0008] The object of the invention is to configure and arrange a modular exhaust manifold in such a manner that a simple and cost-effective design is ensured.
[0009] According to the invention, said object is achieved due to the facts that the manifold pipe module is made of sheet metal and has only one inlet connecting piece at a time and that the formation of the length a of the overlapping contour allows a variation of the insertion depth t by at least 5 mm to 15 mm or by at least 5 mm to 100 mm or by at least another integral value of the ninety-six values between 4 mm and 101 mm, wherein the insertion depth t is fixed by welding the manifold pipe module to the manifold pipe module inserted therein, wherein it may be advantageous if the length a exceeds the desired variation of the insertion depth t by at least 2 mm, i.e., if it is at least 7 mm to 102 mm or has another integral value of the ninety-six values between 6 mm and 103 mm, whereby the distances between the manifold pipe modules can be varied to a sufficient extent and the manifold pipe modules can thus be used to construct manifolds that vary in geometry, particularly out of consideration for the varying distances between the cylinder outlets of different cylinder heads. The inventive dimension ensures a minimum covering of 2 mm that, on the one hand, allows the telescoped overlapping contours to be connected (e.g., by welding or soldering) and, on the other hand, is large enough to allow thermally caused relative motions between the telescoped internal pipes, the latter being allowed because the length of the internal pipes only increases starting from the cold mounting state and the covering consequently increases.
[0010] Moreover, the respective overlapping contour can be adjusted to the desired installation space conditions by shortening thereof so that the insertion depth t or the covering of the overlapping contours can be reduced to the suitable and desired dimension, particularly against the background of the production of only one or few shapes of the manifold pipe module with large lengths a for all conceivable cylinder heads.
[0011] The close sliding fits or plug-type connectors known from DE 103 28 027 A1 or DE 199 23 557 A1 mentioned above that make a change in length possible in principle are insufficient because they only make a compensation for the thermally caused relative motions between the internal pipes or for the production-related tolerances possible. Any additional variation of the distances out of consideration for different cylinder head geometries will not be allowed by the exhaust manifold described herein if only because the pipe sections are conical in the region of the plug-type connector.
[0012] Advantageously, each manifold pipe module may be provided with a separate outer shell module and be a double-walled air-gap-insulated module. Thus, the manifold pipe module configured as a hinged shell does not have to be tight any more so that the joining process for said module can be reduced to the minimum. It is, however, absolutely necessary that the outer shell module or the outer shell formed in this way is tight.
[0013] Said object is also achieved due to the facts that the manifold pipe module is made of sheet metal, wherein each manifold pipe module is provided with an outer shell module and is a double-walled air-gap-insulated module, wherein there is only one inlet connecting piece per module, and that the formation of the length a of the overlapping contour makes a variation of the insertion depth t of at least 5 mm to 100 mm possible, wherein the insertion depth t is fixed by welding the outer shell module to the outer shell module inserted therein.
[0014] It may be particularly important for the present invention if the outer shell module is configured as a hinged shell, wherein in the region of the inlet connecting piece, the outer shell module is so connected to the engine flange as to be gas-tight and the manifold pipe module is so connected to the outer shell module and/or to the engine flange as to be gas-tight. The outer shell module has to be root-penetration-welded in the region of the inlet connecting piece in order to ensure tightness also in the region of the engine flange.
[0015] Concerning this, an advantage may also consist in shaping all manifold pipe modules identically, with no more than two exceptions regarding the collector pipe module and/or the first manifold pipe module, so that only one manifold pipe module shape that can be used to form any manifold needs to be produced at best. If this is not desired (e.g., for installation space reasons), it will be necessary to provide one further shape for the collector pipe module and/or one further shape for the first manifold pipe module in the row in addition to that one shape mentioned above.
[0016] It may also be advantageous if the manifold pipe module is configured as a hinged shell with two joining surfaces that can be placed against each other, wherein the joining surface is root-penetration-welded in the region of the inlet connecting piece. The hinged shell has two advantages. On the one hand, the production thereof is cheaper than that of a hydroformed part. On the other hand, uniform wall thicknesses can be reproduced, which cannot always be ensured with T-shaped hydroformed parts.
[0017] In connection with the inventive configuration and arrangement, a manifold pipe module in the form of a hydroformed part or in the form of a two-shell manifold pipe module made up of two separate shells as an alternative to the hinged-shell design may be advantageous, particularly with larger piece numbers where specific tooling costs are lower.
[0018] It may be advantageous in principle if the manifold pipe module has an overlapping contour in the form of a taper and the outer shell module of the manifold pipe module to be connected has an overlapping contour in the form of an expanded portion in this connecting zone. Thus, the gap between the manifold pipe module and the outer shell module formed in the connecting zone is not narrowed or at least insignificantly narrowed. The overlapping areas or zones having changed diameters, i.e., the taper of the manifold pipe module and the expanded portion of the outer shell module, provide sufficient space for doubling the wall thicknesses of the two overlapping zones. The overlapping contour of the manifold pipe module serves as a guide between the manifold pipe modules to be telescoped that are not accessible any more on account of the outer shell modules that have to be telescoped as well.
[0019] It may also be advantageous if a sealing element is provided, by means of which the first manifold pipe module or the outer shell module is sealed at the free end. The free end of the first module in the row has to be sealed because the manifold pipe modules are identical components. The free end of the last manifold pipe module or of the collector pipe module has the contact flange for connecting an exhaust system so that it does not have to be sealed.
[0020] It may also be advantageous if the manifold pipe modules have seals, such as graphite rings, in the region of the overlapping contour. The seals or sealing rings may be provided on the overlapping contour that has to be slipped on and/or on the overlapping contour that has to be inserted. The connection between the telescoped manifold pipe modules is sealed by means of the seals or sealing rings. Additionally or alternatively, corresponding seals may also be provided for the respective outer shell module. The sealing ring is installed between the two modules to be connected, wherein it is installed in such a manner that it is radially pressed between the inner shell and the outer shell to a sufficiently high extent so that the close sliding fit formed in this way is gas-tight. For this purpose, the sealing ring is fixed, having positive and/or non-positive fit, either on the inner shell and/or on the outer shell in an axial direction by means of a holding geometry so that the axial alignment of the sealing ring is fixed at least with respect to the inner shell or the outer shell.
[0021] It may also be advantageous if the manifold pipe modules are coupled by means of an expansion component. Said expansion component may be, e.g., a folding pipe or a folding-pipe section or a bellow expansion joint connected to both manifold pipe modules to be connected. For forming this connection, one may also use an overlapping contour that allows a sufficiently wide variation of the distances between adjacent manifold pipe modules or manifold pipe modules to be connected. Alternatively, for the two-shell solution, corresponding expansion components may also be provided for the respective outer shell module. The expansion component can also be used as an adapter for accommodating the respective front side to be connected. For this purpose, the expansion component has an appropriate overlapping contour.
[0022] Concerning this, it may be advantageous if the exhaust manifold is configured for heavy-duty applications according to any one of the preceding claims.
[0023] According to the inventive method, it may be advantageous if several such manifold pipe modules are telescoped, by means of the overlapping contour, in the number of the exhaust channels of the cylinder head to be connected, the insertion depth t is adjusted, when telescoping, to the respective architecture of a cylinder head and to the distances between the exhaust channels of the cylinder head to be connected that result from said architecture, and two manifold pipe modules at a time are so connected by welding as to be gas-tight, wherein they are connected directly.
[0024] Concerning this, it may also be advantageous according to the inventive method for producing two-shell manifolds if the closed manifold pipe module is put into an outer shell module configured as a hinged shell, the outer shell module is closed in the region of the joining surface and so closed there by form closure or by firmly bonding as to be gas-tight, the engine flange is welded onto the inlet connecting piece, several such submodules consisting of an outer shell module and an integrated manifold pipe module are telescoped, by means of the respective overlapping contour, in the number of the exhaust channels of the cylinder head to be connected, the insertion depth t is adjusted, when telescoping, to the respective architecture of a cylinder head and to the distances between the exhaust channels of the cylinder head to be connected that result from said architecture, and two submodules at a time are so connected to each other, by welding the outer shell modules, as to be gas-tight, wherein they are connected directly.
[0025] Coupling may be performed by means of form closure or by firmly bonding or by using a sealing ring that is located between the inner shell and the outer shell and sealingly contacts the inner shell and the outer shell in a radial direction.
[0026] It may also be advantageous if the inlet connecting piece is shortened, by cutting off, prior to being connected to the engine flange, said shortening being performed according to the present installation space conditions. Thus, the module can be adjusted to the installation space conditions with respect to the distance from the cylinder head as well.
[0027] It may also be advantageous if the outer shell module is so connected to the engine flange as to be gas-tight and the manifold pipe module is so connected to the outer shell module and/or to the engine flange as to be gas-tight. Advantageously, both modules are connected to the flange in one operation, wherein three components can be handled with one weld seam in this case.
[0028] It is also possible to connect the inner shell to the outer shell and to connect the outer shell to the flange afterwards.
[0029] It may be advantageous if a guide for the manifold pipe module is provided when the outer shell module is connected to the outlet flange. Guiding the manifold pipe modules relative to each other by means of the overlapping contours ensures the correct distance between the outer shell module and the manifold pipe module.
[0030] It may also be advantageous if the first manifold pipe module and/or the outer shell module are/is sealed, by means of a sealing element, in the region of the overlapping contour that is still free or open. Thus, a modular manifold can be produced from identical components in a simple and cost-effective manner without using a separate end pipe piece. The sealing elements to be used are always identical for single-shell or two-shell manifolds as well and serve to seal the inner shell or the outer shell on the front side thereof.
BRIEF DESCRIPTION OF THE INVENTION
[0031] Further advantages and details of the invention are explained in the patent claims and in the description and illustrated in the figures in which
[0032] FIG. 1 a shows a sectional view of a modular exhaust manifold;
[0033] FIG. 1 b shows a perspective side view according to FIG. 1 a;
[0034] FIG. 2 shows a sectional view of a further embodiment;
[0035] FIG. 3 shows a sectional view according to the embodiment of FIG. 2 with four modules;
[0036] FIG. 4 shows a sectional view of an exhaust manifold with four modules and additionally shows seals;
[0037] FIG. 5 shows an embodiment according to FIG. 4 with a changed arrangement of the seal;
[0038] FIG. 6 shows a sectional view of a modular manifold with expansion components between the modules;
[0039] FIG. 7 a shows a sectional view of a modular two-shell manifold;
[0040] FIG. 7 b shows a perspective side view according to FIG. 7 a.
DETAILED DESCRIPTION OF THE INVENTION
[0041] An exhaust manifold 1 according to FIG. 1 a has three manifold pipe modules 1 . 1 to 1 . 3 . The respective manifold pipe module has an inlet connecting piece 1 . 1 a to 1 . 3 a, to which one engine flange 2 . 1 to 2 . 3 at a time is attached. The first manifold pipe module 1 . 1 is arc-shaped, whereas the two manifold pipe modules 1 . 2 and 1 . 3 are identical in shape. The manifold pipe modules 1 . 2 , 1 . 3 are basically T-shaped and are telescoped to an insertion depth t by means of an overlapping contour 1 . 1 b, 1 . 2 b of a length a. An overlapping contour 1 . 3 b of the third manifold pipe module 1 . 3 serves to accommodate a contact flange 1 . 5 for connecting to an exhaust system that is not shown in further detail. The aforementioned engine flanges 2 . 1 to 2 . 3 serve to connect to a cylinder head (not shown) or to cylinder outlets (not shown).
[0042] The first manifold pipe module 1 . 1 is arc-shaped and has, in contrast to the second and third manifold pipe modules 1 . 2 , 1 . 3 , an overlapping contour 1 . 1 b with a diameter that is not tapered in comparison with the other portion of the pipe bend. In principle, a taper of the overlapping contour 1 . 1 b is conceivable as well. In contrast thereto, an overlapping contour between the illustrated manifold pipe modules 1 . 1 to 1 . 3 could also be realized by expanding the diameter instead of reducing it. The expanded portion is slipped on the adjacent manifold pipe module to an appropriate insertion depth.
[0043] The respective manifold pipe module 1 . 1 to 1 . 3 is configured as a hinged part that is kept and connected in the illustrated pipe shape by means of appropriate joining surfaces 1 . 2 c, 1 . 3 c. The arc-shaped first manifold pipe module 1 . 1 is not configured as a hinged part because the simple arc shape of the pipe is a simple standard geometry. The diameters of the respective inlet connecting pieces 1 . 1 a to 1 . 3 a are not tapered, either. This is because the respective engine flange 2 . 1 to 2 . 3 has an appropriately large inner diameter.
[0044] By means of the overlapping contour 1 . 1 b, 1 . 2 b, the configuration of the manifold pipe modules 1 . 1 to 1 . 3 can be varied with respect to the distances between the inlet connecting pieces 1 . 1 a to 1 . 3 a or between the engine flanges 2 . 1 to 2 . 3 . By varying the insertion depth t, the distances between the aforementioned engine flanges 2 . 1 to 2 . 3 can be varied within the range of the realizable insertion depth and can be adjusted to different engine or cylinder head geometries to this extent. The length a of the overlapping contour is approximately 15 mm so that the insertion depth t cannot be more than 15 mm in principle or can be reduced to a minimum dimension of 2 mm if larger distances are used so that the distance between two engine flanges can be varied by exactly 13 mm.
[0045] According to the exemplary embodiment of FIG. 2 , all three manifold pipe modules 1 . 1 to 1 . 3 are identical in shape. The second manifold pipe module 1 . 2 is slipped on the overlapping contour 1 . 1 b of the first manifold pipe module 1 . 1 , whereas the third manifold pipe module 1 . 3 is slipped on the overlapping contour 1 . 2 b of the second manifold pipe module 1 . 2 . The open end 1 . 1 e of the first manifold pipe module 1 . 1 is sealed by means of a sealing element 4 , whereas the open end 1 . 3 e of the third manifold pipe module 1 . 3 has, as in the exemplary embodiment of FIGS. 1 a and 1 b, the contact flange 1 . 5 for connecting to a downstream exhaust system.
[0046] According to the exemplary embodiment of FIG. 3 , the modular exhaust manifold 1 has, in contrast to the exemplary embodiment of FIG. 2 , a total of four manifold pipe modules 1 . 1 to 1 . 4 . The manifold pipe modules 1 . 1 to 1 . 4 are telescoped, corresponding to the exemplary embodiment of FIG. 2 , by means of the corresponding overlapping contour 1 . 1 b to 1 . 3 b, wherein the open end 1 . 1 e of the manifold pipe module 1 . 1 is correspondingly provided with the sealing element 4 and the fourth manifold pipe module 1 . 4 has the contact flange 1 . 5 at the open end 1 . 4 e.
[0047] In the exemplary embodiment according to FIG. 4 , four manifold pipe modules 1 . 1 to 1 . 4 are provided as well. In contrast to the exemplary embodiments of FIGS. 1 a to 3 , the respective overlapping contour 1 . 1 b to 1 . 4 b is configured as a diameter expansion that enables the adjacent manifold pipe module to be slipped on. Moreover, a sealing ring 5 . 1 to 5 . 4 is provided in the region of the overlapping contour configured in this way, said sealing ring sealingly contacting the cylindrical overlapping contour 1 . 2 b to 1 . 4 b along the periphery. The manifold pipe module 1 . 1 to 1 . 3 that carries the seal has, at the corresponding open end, a holding geometry 1 . 1 d to 1 . 3 d for supporting or fixing the sealing ring 5 . 1 to 5 . 3 . The holding geometry 1 . 1 d to 1 . 4 d is configured as a toric enlargement in comparison with the main diameter, said toric enlargement cooperating with an expanded portion on the front side so that the respective sealing ring 5 . 1 to 5 . 3 is embedded, over part of its thickness, in the ring channel formed in this way and cannot slip axially. In the region of the open end of the fourth manifold pipe module 1 . 4 , the aforementioned holding geometry for a sealing ring to be provided is not provided because the contact flange 1 . 5 is attached to this open end 1 . 4 e. In this respect, the shape of the fourth manifold pipe module 1 . 4 differs from that of the first three manifold pipe modules 1 . 1 to 1 . 3 . The exemplary embodiment of FIG. 5 also provides a sealing ring 5 . 2 to 5 . 4 between the manifold pipe modules 1 . 1 to 1 . 4 . In contrast to the embodiment according to FIG. 4 , the embodiment of FIG. 5 provides a holding geometry 1 . 2 d to 1 . 4 d for the respective sealing ring 5 . 2 to 5 . 4 , said holding geometry being provided in the respective overlapping contour 1 . 2 b to 1 . 4 b. The holding geometry 1 . 2 d to 1 . 4 d is configured as a ring-groove-shaped extension of the aforementioned overlapping contour 1 . 2 b to 1 . 4 b so that the respective sealing ring 5 . 2 to 5 . 4 fits closely along the periphery within the aforementioned ring groove, while it sealingly contacts the respective open end of the respective inserted manifold pipe module 1 . 1 to 1 . 3 after slipping on. The open end 1 . 1 e of the first manifold pipe module 1 . 1 has the sealing element 4 , wherein the open end 1 . 1 e of the first manifold pipe module 1 . 1 has a further diameter enlargement 1 . 1 f at the front-side end of the overlapping contour 1 . 1 b. The sealing element 4 is arranged in said diameter enlargement 1 . 1 f.
[0048] According to the exemplary embodiment of FIG. 6 , one expansion component 6 . 1 to 6 . 3 at a time is provided between the four manifold pipe modules 1 . 1 to 1 . 4 . By means of said expansion component, the manifold pipe modules 1 . 1 to 1 . 4 are so connected as to be gas-tight and to exhibit appropriate flexibility, wherein the respective open ends of the respective manifold pipe module 1 . 1 to 1 . 4 are cylindrical without any overlapping contour, wherein the respective expansion component is provided with a correspondingly larger diameter so that it is slipped on the respective open end. Like the sealing element 4 , the expansion components and the flanges 1 . 5 , 2 . 1 to 2 . 4 are so connected (preferably by welding or soldering) to the respective manifold pipe module as to be gas-tight.
[0049] According to the exemplary embodiment of FIG. 7 a , the exhaust manifold 1 is configured as a two-shell air-gap-insulated exhaust manifold. For this purpose, each manifold pipe module 1 . 1 to 1 . 4 has a separate outer shell module 3 . 1 to 3 . 4 , wherein both the respective manifold pipe module 1 . 1 to 1 . 4 and the respective outer shell module 3 . 1 to 3 . 4 have a separate overlapping contour 1 . 1 b to 1 . 1 c, 3 . 2 b to 3 . 4 b, by means of which adjacent manifold pipe modules as well as adjacent outer shell modules 3 . 1 to 3 . 4 are telescoped or slipped on each other. The overlapping contour 1 . 1 b to 1 . 4 b of the manifold pipe module 1 . 1 to 1 . 3 is configured as a taper, whereas the respective overlapping contour 3 . 2 b to 3 . 4 b of the outer shell module 3 . 2 to 3 . 4 is configured as a diameter expansion so that the air gap to be created will not become smaller in the region of the overlapping contours, either, i.e., not smaller than in the other regions. The sealing element 4 is inserted in the open end 1 . 1 e of the manifold pipe module 1 . 1 and also contacts the open end 3 . 1 e of the outer shell module 3 . 1 so that it can be so connected to the outer shell module 3 . 1 there as to be gas-tight. The contact flange 1 . 5 is slipped on the open end 3 . 4 e of the manifold pipe module 1 . 4 as well as on the open end of the outer shell module 3 . 4 and can be so connected as to be gas-tight as desired. As shown in the exemplary embodiment according to FIG. 7 b , the respective outer shell module 3 . 1 to 3 . 4 also has a joining surface 3 . 1 c to 3 . 4 c that is root-penetration-welded particularly in the respective region of an overlapping contour 3 . 1 b to 3 . 4 b or in the region of a respective inlet connecting piece 3 . 1 a to 3 . 4 a or open end according to FIG. 7 a so that a gas-tight connection to the respective engine flange 2 . 1 to 2 . 4 or to the contact flange 1 . 5 or to the sealing element 4 is ensured.
LIST OF REFERENCE NUMERALS
[0050] 1 exhaust manifold
[0051] 1 . 1 manifold pipe module
[0052] 1 . 1 a inlet connecting piece
[0053] 1 . 1 b overlapping contour
[0054] 1 . 1 c joining surface
[0055] 1 . 1 d holding geometry
[0056] 1 . 1 e free, open end
[0057] 1 . 1 f diameter enlargement
[0058] 1 . 2 manifold pipe module
[0059] 1 . 2 a inlet connecting piece
[0060] 1 . 2 b overlapping contour
[0061] 1 . 2 c joining surface
[0062] 1 . 2 d holding geometry
[0063] 1 . 3 manifold pipe module, collector pipe module
[0064] 1 . 3 a inlet connecting piece
[0065] 1 . 3 b overlapping contour
[0066] 1 . 3 c joining surface
[0067] 1 . 3 d holding geometry
[0068] 1 . 3 e free, open end
[0069] 1 . 4 manifold pipe module, collector pipe module
[0070] 1 . 4 a inlet connecting piece
[0071] 1 . 4 b overlapping contour
[0072] 1 . 4 c joining surface
[0073] 1 . 4 d holding geometry
[0074] 1 . 4 e free, open end
[0075] 1 . 5 contact flange
[0076] 2 . 1 engine flange
[0077] 2 . 2 engine flange
[0078] 2 . 3 engine flange
[0079] 2 . 4 engine flange
[0080] 3 . 1 outer shell module
[0081] 3 . 1 a inlet connecting piece
[0082] 3 . 1 b overlapping contour
[0083] 3 . 1 c joining surface
[0084] 3 . 1 e free, open end
[0085] 3 . 2 outer shell module
[0086] 3 . 2 a inlet connecting piece
[0087] 3 . 2 b overlapping contour
[0088] 3 . 2 c joining surface
[0089] 3 . 3 outer shell module
[0090] 3 . 3 a inlet connecting piece
[0091] 3 . 3 b overlapping contour
[0092] 3 . 3 c joining surface
[0093] 3 . 4 outer shell module
[0094] 3 . 4 a inlet connecting piece
[0095] 3 . 4 b overlapping contour
[0096] 3 . 4 c joining surface
[0097] 3 . 4 e free, open end
[0098] 4 sealing element
[0099] 5 . 1 seal, sealing ring
[0100] 5 . 2 seal, sealing ring
[0101] 5 . 3 seal, sealing ring
[0102] 5 . 4 seal, sealing ring
[0103] 6 . 1 expansion component
[0104] 6 . 2 expansion component
[0105] 6 . 3 expansion component
[0106] a length
[0107] t insertion depth
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A modular exhaust manifold 1 for a motor vehicle, with multiple adjoining manifold pipe modules, having: at least one engine flange, via which an inlet connection pipe of the manifold pipe modules can be connected to a cylinder head of the motor vehicle; at least one manifold pipe module, configured as a collector pipe module and having a contact flange, via which the exhaust manifold can be connected to an exhaust system of the motor vehicle, the respective manifold pipe modules having an overlap contour of a length a that permits the telescoping of two manifold pipe modules to an insertion depth t for coupling purposes, at least two manifold pipe modules being identical in shape, and a variation of the insertion depth t of at least 5 mm to 30 mm or 10 mm or 15 mm or 20 mm or 25 mm being obtained by the formation of length a of the overlap contour. A method for producing a manifold formed from multiple adjoining manifold pipe modules.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a divisional of allowed, U.S. application Ser. No. 10/485,079, filed Jan. 27, 2004, now U.S. Pat. No. 6,931,166 which is a national stage of international application PCT/US02/34377, filed Oct. 25, 2002, which claims the benefit of U.S. provisional application No. 60/343,724, filed Oct. 25, 2001, each of which is hereby incorporated by reference in its entirety.
STATEMENT OF GOVERNMENTAL INTEREST
This invention was made with U.S. Government support under Navy contract no. N00024-98-D-8124. The U.S. Government has certain rights in the invention.
BACKGROUND OF THE INVENTION
The present invention relates to sensors and in particular to optical sensors. There are both electrical and optical sensors capable of sensing pressure, stress, and penetration of objects. However, present electrical penetration sensors detect penetration of the sensor by a projectile via electrical shorts in the sensor. The penetrating projectile creates the short between two separated conductive layers. This short can be sensed and used to identify a penetration. One of the drawbacks of electrical sensors is the problem of inadvertent shorts of the two separated conductive layers. The conductive layers must be insulated from each other and the other conductive parts of the sensor and from the structure on which the sensor is mounted. This adds to the design, installation, and the overall troubleshooting and maintenance costs of the sensor. Electrical sensors can also generate inadvertent sparks, which in some applications, where explosives might be nearby, is highly undesirable. Electrical sensors are also subject to electrical noise that is generated from electromagnetic interference. Many situations where the detection of penetration is desirable are located close to highly explosive events, which events have been know to generate electrical noise. Noisy electrical signals can be difficult to interpret and can cause erroneous indication of penetration events. Another drawback of using electrical sensors is that the passing projectile can short out the signal cable. This event can erroneously be interpreted as a penetration event at the sensor or, even worse, short out the power supply and cause erroneous readings on other sensors that are connected to the same system. Electrical sensors have also proven to be susceptible to chemicals, which limits their applications.
Current optical sensors are not subject to the shorting problem. For example, ITT Industries, Advanced Engineering & Sciences of Reston, Va. offers a Photonic Hit Indicator. That sensor includes a grid of optical fibers. A projectile that penetrates the sensor cuts some of the optical fibers. Detection of the loss of optical signal in the severed fiber is used to identify the location of the projectile's penetration. This sensor is, however, an active sensor. That is, it requires light to be applied to the optical fibers of the sensor. Severing of the optical fibers by the penetrating projectile prevents the applied light from reaching photodetectors. Detecting the absence of the applied light on the optical fiber of the grid provides an indication of where the projectile penetrated the sensor. One disadvantage of this type of sensor is that a fine and precise layout of many optical elements is needed to achieve a fine spatial resolution of the impact point. In addition, such active layouts of optical fibers are expensive to manufacture. Also, like electrical sensors, they require power to drive the light source or sources for the optical fibers or fibers.
The prior art sensors discussed above provide for penetration time and location. They do not directly provide additional details on the trajectory of the projectile or other penetration characteristics of the projectile. In addition, both methods discussed above degrade significantly as projectile damage accumulates in multiple projectile scenarios. In the case of the electrical detection panels, a penetrating fragment will often leave the panel shorted out. Once a panel is shorted, it cannot detect the penetration of subsequent projectiles. In the case of the Photonic hit indicator, once a projectile penetrates, it creates blind spots at other locations where the same optical fibers run; each optical element is only capable of registering the first projectile passing through.
There are other systems that employ high-speed imaging to measure projectile trajectories. These systems are expensive to purchase and operate and are limited in use to very specific applications.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an inexpensive optical sensor.
It is a further object of the present invention to provide an optical sensor that does not require power.
It is another object of the present invention to provide an optical sensor that does not require an external light source.
It is still a further object of the present invention to provide an optical sensor structure for detecting the speed and direction of a projectile.
It is still a further object of the present invention to provide an optical sensor structure for detecting the impact location of a projectile.
It is still another object of the present invention to provide a passive optical sensor structure for detecting the speed and direction of a projectile.
It is still another object of the present invention to provide a passive optical sensor structure for detecting the impact location of a projectile.
It is still another object of the present invention to provide a passive optical sensor structure for reliably detecting the trajectory of more than one projectile in succession.
It is still another object of the present invention to provide a passive optical sensor structure for detecting multiple nearly simultaneous trajectories of projectiles.
Another object of the present invention is to provide a method of determining a path of a projectile.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded schematic representation of an optical sensor embodying the present invention.
FIG. 2 is a schematic representation of an optical sensor structure embodying the present invention.
FIG. 3 is a schematic representation of the FIG. 2 optical sensor structure viewed along the XY plane.
FIG. 4 is a schematic representation of the FIG. 2 optical sensor structure viewed along the XZ plane.
FIG. 5 is a schematic block diagram of a detection system embodying the present invention with a single optical fiber transmitting an optical signal from each optical sensor to a corresponding detector.
FIG. 6 is a schematic block diagram of a detection system embodying the present invention with a single optical fiber transmitting all optical sensor signals to a single detector.
FIG. 7 is a schematic block diagram of a detection system embodying the present invention with a single optical fiber transmitting all optical sensor signals to an array of detectors.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is an exploded schematic representation of an optical sensor embodying the present invention. In FIG. 1 , reference numerals 10 and 30 identify opaque layers. These layers shield a light generator layer ( 15 , 20 , 25 ) from ambient light. The composition of the opaque layers depends upon the sensor application and the expected ambient light. Some exemplary materials that can be used in the opaque layers 10 and 30 include, but are not limited to, optically opaque plastics such as polycarbonates (e.g., Lexan®) and acrylics (e.g., Plexiglas®), structural fiber reinforced composites, metals (e.g., copper), and silicone molding compounds. In the exemplary embodiment shown in FIG. 1 , the light generator layer ( 15 , 20 , 25 ) includes reflective layers 15 and 25 , together with a transparent layer 20 .
The reflective layers 15 and 25 can comprise, for example, optically reflective plastics such as mirrored polycarbonate (e.g., Lexan®) and acrylic (e.g., Plexiglass®), metal alloy films (e.g., aluminized polyimide-based Kapton®), and highly polished metals. In an exemplary embodiment, the transparent layer 20 can comprise, for example, optically clear plastics such as polycarbonates (e.g., Lexan®) and acrylics (e.g., Plexiglass®) and silicone-based molding compounds such as conformable gels. The transparent layer can also comprise a gas, such as, for example, air, or nitrogen. However, if using a gas for the transparent layer 20 , the light sensed by the fiber optic 35 , would be primarily generated by a projectile passing through reflective layers 15 and 25 and some portion of the transparent layer may require additional solid supports to maintain the structure.
In general, the optical sensor shown in exploded form in FIG. 1 , is a stack of materials designed to provide an optical pulse to the optical fiber, 35 , when a sufficiently energized projectile hits and/or penetrates the stack. The optical sensor of the present invention is generally planar. The layers of the sensor are planar in that they have a generally constant thickness along the length and width dimensions of the sensor. They can be constructed to be flexible and to conform to a desired structure of interest while substantially maintaining the thickness of the sensor layers along the length and width dimensions of the sensor. The sensor layers can be cut and/or machined to match pre-existing surfaces. The purpose the optical sensor of the present invention is to provide the time of passage of a projectile through the light generator layer to some external measurement system that is capable of converting the optical pulse into electronic form for storage and/or processing. The value of the information contained within the generated light pulse is specific to each application. The spatial resolution of detection for single element optical sensors of the present invention corresponds to the area of the sensor. The temporal resolution of the measurement is determined by the rate at which the optical fiber is sampled. Since the optical sensor of the present invention is passive, it is intrinsically safe for use in explosive environments and immune to electromagnetic interference.
FIG. 2 is a schematic representation of an optical sensor structure embodying the optical sensor of the present invention. By using multiple optical sensors in accordance with the present invention in a suitable geometrical arrangement, additional information regarding the nature of the projectile can be obtained. FIG. 2 schematically illustrates an exemplary one of such suitable geometrical arrangements. By employing the exemplary geometric arrangement shown in FIG. 2 , additional information that can be computed includes: (1) the penetration location of the projectile on the face of the panel; (2) the three spatial components of projectile velocity; and (3) the speed attenuation factor of the projectile.
An example method for computing (1), (2), and (3) is shown in the exemplary MATLAB code listing below. The velocity attenuation factor (R) of a projectile pertains to the manner in which the projectile loses energy as it passes through the layers of the optical sensors. For a given optical layer, R is defined as the ratio of Vin to Vout, that is, the velocity upon reaching the plane and the velocity upon leaving the plane. For a given optical sensor structure, the velocity attenuation that occurs during the passage through each optical sensor layer is a function of the projectile velocity and size and the composition of the optical sensor structure layers. Since the optical sensor structure can detect the time at which a projectile reaches a given layer of the structure, the times can be used to measure the projectile velocity attenuation factor R. It is also possible to characterize various projectiles by using this additional information. The FIG. 2 structure includes seven optical sensors positioned in seven planes ( 40 , 50 , 55 , 60 , 65 , 70 , and 45 ). The optical sensors can be of the type shown in FIG. 1 , but are not limited to such sensors. The use of a seventh optical plane ( 45 ) in the structure allows for an independent measure of the velocity attenuation R. In the absence of this plane, R must be assumed and significant error can occur in the computation of the projectile parameters. If R is not equal to unity, then the mathematics of computing the projectile trajectory is more complicated, since the velocity will change in a step-wise manner as it penetrates the layers of the optical sensor structure. Because the projectile velocity attenuates as it passes through the optical structure, the measured times corresponding to when the projectile passes each plane should be modified in a specific way prior to the computation of the projectile parameters. The addition of the seventh plane ( 45 ) allows for the computation of R. The computation of R then allows the measured penetration times to be corrected for what they would have been if no velocity attenuation had occurred. While the use of the attenuation factor, R, complicates the computational steps, the independent measurement of R provides for a much more accurate trajectory reconstruction. The basic logic is reflected in the exemplary MATLAB code below. The attenuation factor, R, is computed by finding the real root of a fifth order polynomial. Then a matrix is constructed to contract the measured penetration times to what they would have been if R had been unity. The contracted time vector is then used to compute the projectile parameters.
If the initiation time of the projectile motion is also known or measured, then the original location of the projectile at the initiation time can be computed. It is not necessary that the original location is in front the first plane, 40 . It can just as well be beyond the last plane, 45 . This process is also reflected in the exemplary MATLAB code listing below. If the initiation time measurement is in error, then the computed projectile velocities will still be accurate but the computed initial location will be in error.
If the origination position of a projectile is desired, then the initiation time is needed to determine that position. The measurement of initiation time may be performed differently for different applications. In the case of a bright flash in close proximity, an optical pickup fiber or a photodiode can be used. If an optical fiber is used, it can be attached to the optical sensor structure. The optical fiber should have a large numerical aperture to be able to receive light from many directions. The end of the fiber should be oriented in the expected location of the origination flash. If it is unknown apriori whether the origination flash will occur in front of or behind the sensor structure, then two optical fibers may be used, one looking aft and one looking forward. The two optical fibers may then be joined into one at a 2-to-1 optical coupler. The exemplary MATLAB code uses the parameter t_mark as the initiation time of the projectile. The exemplary code processes the temporal signals with t=0 defining the time when the projectile penetrates first plane, 40 . Therefore, t_mark may in fact be negative. If a data system is used that sets t=0 as the initiation time of the projectile. The times need to be shifted so that the penetration of the first plane corresponds to t=0 prior to using the exemplary MATLAB code as is. Care should be exercised if using this approach to ensure that the response time of the initiation detection is minimal. In the case of a more distant flash with audible report from, for example, a bullet, the computation of initiation time would use the local temperature and pressure to compute the sound speed first. This allows for the time that it takes the sound to travel to the audible sensor from the projectile motion-initiating event, such as an explosion or gun firing. The time that the projectile arrives at each layer of the optical sensor structure shown in FIG. 2 is detected via the light pulse generated in each corresponding layer of the structure. These times can be used to compute the three spatial components of the projectile velocity, the impact location, and the speed attenuation factor. With the projectile velocity and the sound speed both known quantities, the initiation time of the projectile motion can then be computed since the distance that the sound travels and the distance that the projectile travels are of course equal.
Referring to FIG. 2 , if simultaneous arrival of multiple projectiles with differing trajectories at the structure occurs, then the optical signals produced by the structure can be quite complex. The ability to resolve multiple projectiles is dependent on the particular circumstances. Generally, the multiple projectiles are still resolvable as long as the optical signal from one does not mask the optical signal from another. Masking can occur if two fragments pass through the same plane simultaneously. In some cases, it is possible to resolve multiple trajectories even if limited masking occurs, since the absence of some portions of one trajectory could indicate when the masked signal would have had to have been generated. It is advantageous to keep the optical pulse width that is generated by each penetration as narrow as possible to limit masking as long as the data acquisition system is capable of resolving it. The pulse width can be reduced by adding thermally conductive material to the light generator layer. Such materials might include diamond or metallic thin films or particulates. This reduces the pulse width by rapidly dispersing the heat that is generated during penetration. Photochromic dyes and polymers can also be used to reduce the pulse width. These materials work by reducing optical transmissibility as the signal intensity rises. If multiple projectile penetrations occur, the penetration times associated with each projectile must be separated prior to using the exemplary MATLAB code. The system configuration can be simplified by using multiple planar elements that are connected to a single optical fiber through a 7-to-1 optical connector (such as schematically shown as element 155 in FIG. 6 ), rather than each optical sensor layer having its own optical fiber connected thereto as schematically shown in FIG. 5 . Thus, only one fiber has to transmit the optical signal to the associated computer for processing in accordance with, for example, the exemplary MATLAB code shown below. It will be understood by those skilled in the art that the exemplary MATLAB code is just that, an example. The invention is not restricted to any given implementation, and can obviously be implemented in a variety of different procedures. One way to use the 7-to-1 optical connector and still be able to resolve multiple penetrations is to spectrally modify the light generated by each layer. This can be accomplished by doping the transparent or reflective layers to tailor the wavelength band that enters the fiber for each plane. The optical filtering could alternatively be performed by using optical filters at the 7-to-1 optical connector. If this technique is used, then seven independent detector channels would be used on the receiving end, each of which is designed to respond to a particular wavelength, such as schematically shown in FIG. 7 .
If only one optical fiber is used together with, for example, the 7-to-1 optical connector, then the relaxation time from a single penetration should be less than the inter-panel transit time within the optical sensor structure. This can be realized by choosing materials that rapidly distribute the heat generated when a projectile passes through or alternatively by using special optical materials that reduce optical transmissibility as the intensity rises. Examples of such materials that exhibit photochromic characteristics include silver halide, tungsten oxide, titanium dioxide and other photochromic dyes and polymers. In addition, exemplary heat-dissipative materials could include diamond or metallic films or particulates. As long as the photodiode that is operatively coupled to the fiber optic does not saturate, an AC coupled filtering circuit can also be used to improve the ability to resolve a penetration at a particular optical sensor layer at a particular time within the optical sensor structure. The use of AC coupled filtering circuits effectively extends the dynamic range of the detectors.
The exemplary embodiment of an optical sensor structure shown in FIG. 2 includes 21 elements. It includes seven optical sensors ( 40 , 50 , 55 , 60 , 65 , 70 , and 45 ) positioned in respective planes. These optical sensors are identified with the reference letter (P). The exemplary FIG. 2 structure also includes six rectangular spacer panels, and eight triangular wedge panels. These elements are not shown in FIG. 2 , but are shown in FIGS. 3 and 4 .
In FIGS. 3 and 4 , the spacers are identified with the reference letter (S), and the wedges are identified with the reference letter (W). In FIGS. 3 and 4 , two of the eight wedges are not visible in the particular perspective shown in the respective figures. The stack-up of the optical sensor structure illustrated in FIG. 3 in the X dimension is PSWPWSWPWSWPWSWPWSPSP. Obviously, the orientation of the wedges depends on the optical sensor layer that it is positioning.
Referring to FIG. 2 , the end optical sensor layers, 40 and 45 , have the dimensions of L×L×S, where L denotes the length and width of each layer, and S is the thickness of the layer. This example uses a square layer, but the shape can be any geometrical shape. The five internal optical sensor layers ( 50 , 55 , 60 , 65 and 70 ) are rectangles that, in the illustrated example, have dimensions determined by the tilt parameter D. In the exemplary embodiment discussed herein, the tilt parameter, D, is equal to the arc tangent of the wedge angle A shown in FIG. 3 . The dimensions of the interior panels are L×Lsec(A)×S, where Lsec(A) is L times the secant of the angle A. In the illustrated example, all wedge elements are identical, and all spacer elements are identical. If these elements are not identical, the calculations illustrated in the MATLAB code below must be adjusted to account for the different shapes. The spacer elements are rectangular and the dimensions are L×L×(H−S), where (H−S) is the thickness of the spacer element. In this way, the thickness of a back-to-back planar element and spacer element is H. The spacers provide a minimum separation distance between all optical sensor layers. The wedges tilt the optical sensor layers into desired planes. The materials for the spacers and wedges should be thermally stable and incompressible but easily penetrable. Incompressibility is desirable so that the geometry of the sensor structure is maintained as the projectile passes through. Example materials include plastics (polycarbonates (e.g., Lexan®)), silicone gel compounds, and fiber reinforced and non-reinforced polyimide-based composite materials.
While the FIG. 2 structure illustrates one example of the orientation for optical sensors, may other orientations are possible. With reference to FIG. 2 , the primary axis of the structure is the X axis because most of the projectile movement is confined to this dimension. The X dimension in the example structure is unique because the plane of the first optical sensor ( 40 ) corresponds to X=0 and therefore a pulse from this sensor corresponds directly to when the X dimension of projectile position is equal to zero. No extra computations are required to discern this, as it is a direct result of the geometry of the sensor structure and how the coordinate system was defined. The first and sixth optical sensors in FIG. 2 ( 40 , 70 ) are parallel and their primary use is the measurement of the X dimension of the projectile velocity. For the Y and Z dimensions in FIG. 2 , projectile characterization is not as straightforward. The reason for this is that the impact position in the first sensor ( 40 ) is not known apriori. For purposes of an optical sensor structure according to the present invention, pairs of additional optical sensors should be positioned in at least two inclined planes for each additional dimension of interest for the projectile parameters. For example, inclined sensors 50 and 55 in FIG. 2 are used to measure the two projectile parameters that are associated with the Y dimension, namely the impact location y 0 and the Y component of projectile velocity Vy. Similarly, inclined sensors 60 and 65 are used to measure the Z dimension information. The specific structure illustrated in FIG. 2 is not the only structure that could yield full three-dimensional information regarding the projectile; however at least two planes are need for each dimension of interest and they must be inclined with respect to the primary axis of the structure if both impact position and the velocity component in that particular dimension are desired. In addition, as noted herein, the last sensor ( 45 ), such as the seventh sensor is optional and intended to provide better accuracy by providing an independent way to measure the velocity attenuation factor. The use of the extra sensor to measure the velocity attenuation allows for the computation of the fragment parameters with confidence. Without the extra sensor, the fragment parameter computations can only be performed with assumptions regarding the velocity attenuation, assumptions that could introduce measurement error. Obviously, the reference to the seventh sensor is with respect to the FIG. 2 structure. If, for example, basic optical sensor structure in accordance with the present invention has only four sensors, the optional sensor would be a fifth sensor.
As described with reference to the illustrative embodiment shown in FIG. 1 , the illustrated optical sensor includes five layers. Referring to FIG. 1 , those layers include a transparent layer 20 also labeled as “T” in FIG. 1 . The transparent layer 20 or T is sandwiched between two reflective layers 15 and 25 that are also labeled as “R” in FIG. 1 . The reflective layers 15 and 25 are in turn sandwiched between two opaque layers 10 and 30 which are also labeled as “O” in FIG. 1 . The palindrome stack-up of each optical sensor layer is thus ORTRO. As noted above, the opaque layers 10 and 30 function to prevent ambient light from entering device. The reflective layers function to contain light within the transparent layer 20 . The transparent layer 20 couples the light generated by the projectile into an attached optical fiber 35 . The overall stack-up of an optical sensor structure is ORTROSWORTROWSWORTROWSWORTROWSWORTROWSORTROSORTRO. This is a total of 49 elements. An opaque outer jacket is also required around the overall optical sensor structure to preclude ambient light from entering the sensor structure from the edges of the transparent layers of the individual sensor elements. This can be made from the same materials that are used for layers 10 and 30 in the individual sensing elements. Optical fiber attachments to the transparent layers should be secured mechanically to prevent inadvertently dislodging the fiber. Efficient optical coupling is achieved by inserting the optical fiber end directly into the transparent plane of each sensor. Optically clear epoxies can be used to secure the attachment. Alternatively, the optical fibers may be attached edgewise to the transparent planes; however, it is necessary to scratch the outer surface of the fiber by sandblasting or other methods to provide paths for the planar light to enter the fiber. The edgewise attachment method offers advantages for routing the fibers along unobtrusive paths back to the detectors; however, the signal levels are lower, all else being the same. Thus, this method may only be used if the projectile-induced signal levels are large enough to reach the detector thresholds. Interlayer adhesives have not been addressed in the above. The adhesives should have a uniform known thickness. It is also preferable that they do not delaminate pieces of the structure under the intended operational conditions. They are well known to those skilled in the art.
The following discusses some exemplary applications of the present invention.
Single Optical Sensor Layer Applications
A single optical sensor layer embodying the present invention can be used to detect projectiles from an explosive device that impact a surface. In many applications, it is desirable to know when projectiles from an explosive device penetrate at a particular location. The placement of a single optical sensor layer on a surface will allow for the generation of an optical pulse when the projectile impacts and/or penetrates the layer device. The placement of back-to-back layers of the same layer device, with or without a spacer element between them, can provide a rough measure of penetration speed. If it is known that the projectile will penetrate normal to the surface of the two back-to-back layers of the same layer device, then the stack up can be used to compute projectile speed. Tiling of single optical sensor layers can be used to provide for impact coverage over a wider area. By offsetting two tiled layers from each other, additional spatial resolution can be gained.
Other applications include: (1) detection of energetic particles that are capable of generating an optical pulse signature, such as micrometeorite detection; (2) detection of penetration caused by bullets or other high-energy projectiles; and (3) impact detection caused by a localized impulsive force on a surface. By using a material that generates light on impact within any of all of the layers 15 , 20 , and 25 , the light could couple into the optical fiber 35 , and indicate the application of an impulsive force. Examples of materials that can yield flash augmentation can be readily suspended in particulate, filled bubbles, or microsphere encapsulation forms in the optically clear medium include phosphorescent minerals (barium sulfide, calcium sulfide, and strontium sulfide) and chemical elements (phosphorous), combustible metals (magnesium), and reflective metal alloys (aluminum).
Multiple Optical Sensor Layer Applications
An optical sensor structure that includes multiple optical sensor layers embodying the present invention can be used to detect and characterize projectiles incident on a surface from some explosive device. In the case of an explosion, the projectile characterization can allow for accurate determination of the (1) location of the center of the explosion, location of the impact point on a particular panel, e.g., 40 , three-dimensional spatial velocity measurements, and measurement of the velocity attenuation factor R. The exemplary optical sensor structure device shown in FIG. 2 includes seven optical sensor elements in accordance with the present invention. The FIG. 2 structure is capable of resolving impact location and the speed and direction, i.e., the velocity vector of a projectile relative to a coordinate system defined by the construction of the optical sensor structure such as shown in FIG. 2 . The FIG. 2 structure is also capable of measuring the velocity attenuation factor associated with projectile penetration. If the initiation time of the explosive device is also known, then the structure is also capable of determining the source position of the projectile at the initiation time. This has immediate application for targets used in missile defense tests. In the case of fragmenting devices, when the time of initiation is known, the FIG. 2 structure can be used to compute the location of the fragmenting device relative to the target vehicle. In the case of target damage projected by kinetic encounter, the FIG. 2 device can be used to provide critically important trajectory data as well. These data can greatly enhance the post-intercept lethality assessment process. The FIG. 2 structure can also be used in live fire testing as a diagnostic tool to identify the center of an explosion.
Another example application is in forensic post-detonation bomb characterization. In high threat locations for explosive devices, a multichannel optical sensor layer, such as shown in FIG. 2 , could be installed in advance. If an explosion were to occur, the optical sensor structure could provide valuable forensic evidence that could be used to piece together critical information such as the original location of the bomb and energy content. This information could help investigators to solve crimes. It is particularly useful in that it is not necessary to have the device available after a measurement has occurred. The data record that is transmitted from the device is sufficient to reconstruct the events and characterize the explosion. For example, a FIG. 2 type structure could be used in airplanes to provide forensic evidence of an explosive event if the data from the FIG. 2 structure was recorded in the Flight Data Recorder. In this application, it would be very important to protect the optical fiber that transmits the data to the recorder location.
A FIG. 2 type structure could also be used by bomb squads as a device to characterize a bomb at the time of detonation. Rather than simply detonating a dangerous device, the structure could be used to provide valuable information to characterize the device, such as the mass of projectiles emanating from the bomb.
Another application is in determining the source of a gunshot. The optical sensor structure such as shown in FIG. 2 can be packaged into a portable system that would allow moving infantry to immediately resolve the source position of a gunshot fired by a sniper and provide a measure of the bullet velocity that can be used to immediately help identify the weapon. In this application, it would also be necessary to accurately know the location and orientation of the optical sensor structure at the time of impact with respect to the coordinate system of interest, the battlespace. The use of the audible sound from the shot could be used with the optical sensor structure data to quickly resolve the origination point of the bullet. This information could then be transmitted to situational awareness framework and appropriate defensive action could be taken without delay. Such a system could be contained on the outside of a soldier's pack, for example, and used to be able to rapidly respond to a sniper attack.
The following provides an illustrative analytical solution for determining projectile parameters. Assume that a projectile penetrates an optical sensor structure such as shown in FIG. 2 . The following analysis demonstrates how a six component temporal vector can be used, together with the structural parameters of the optical sensor structure, to determine the penetration location (y 0 , z 0 ) in plane 1 , which is the plane that optical sensor layer 40 is positioned and to determine the three components of projectile velocity (V x , V y , and V z ). The temporal vector includes the penetration time associated with optical sensors 1 through 6 ( 40 , 50 , 55 , 60 , 65 , and 70 ) positioned in its corresponding plane. Without loss of generality, we are free to define the time when the projectile penetrates plane 1 as t 1 =0, where plane 1 is the plane in which optical sensor 40 is positioned. Therefore X(t 1 )=x 0 =0. The parametric representation for the trajectory of the projectile is given in equations (1) through (3).
X ( t )= V x t (1)
Y ( t )= y 0 +V y t (2)
Z ( t )= z 0 +V z t (3)
This parametric representation assumes that the velocity attenuation factor is equal to unity; the projectile passes through the sensor without slowing down. If this is the case, then the six component temporal vector is sufficient to uniquely resolve the projectile impact location and velocity components. Later in the analysis, a sensor in the seventh plane, 45 , is used to be able to perform the same computations even when R>1.
In the coordinate system of the optical sensor structure shown in FIG. 2 , the equations of the seven planes are in the form shown in equation (4).
X+B j2 Y+B j3 Z=E j j= 1,2,3,4,5,6,7 (4)
The coefficients B j2 , B j3 , and E j are dependent on the geometric parameters of optical sensor structure construction. A simple construction is described that uses three geometric parameters L, H, and D. L is the width of the optical sensor structure in the Y and Z dimensions. H is the thickness of the spacer element less the thickness of the optical sensor layer. D is the product of L and the tangent (A), where A is the wedge angle that is used to construct the wedge elements show in FIG. 3 . With these definitions and the optical sensor structure construction defined, the equations for planes 1 through 6 ( 40 , 50 , 55 , 60 , 65 , and 70 ) are listed in equations (5) through (10).
X=0 plane1 (5)
X+DY =( H+D ) L plane2 (6)
X−DY =(2 H+D ) L plane3 (7)
X+DZ =(3 H+ 3 D ) L plane4 (8)
X−DZ =(4 H+ 3 D ) L plane5 (9)
X =(5 H+ 4 D ) L plane6 (10)
The next step is to substitute the parametric equations for the projectile into the X, Y, and Z variables in the planar equations. The time of penetration of plane j is denoted as t j . The new equations are shown in (11) through (16).
V x t 1 =0 plane1 (11)
V x t 2 +D ( y 0 +V y t 2 )=( H+D ) L plane2 (12)
V x t 3 −D ( y 0 +V y t 3 )=(2 H+D ) L plane3 (13)
V x t 4 +D ( z 0 +V z t 4 )=(3 H+ 3 D ) L plane4 (14)
V x t 5 −D ( z 0 +V z t 5 )=(4 H+ 3 D ) L plane5 (15)
V x t 6 =(5 H+ 4 D ) L plane6 (16)
Equation (11) says that t 1 =0. Equations (12) through (16) can be expressed in the matrix form MP=Q, as shown in equation (17).
( D 0 t 2 Dt 2 0 - D 0 t 3 - Dt 3 0 0 D t 4 0 Dt 4 0 - D t 5 0 - Dt 5 0 0 t 6 0 0 ) ( y 0 z 0 V x V y V z ) = ( ( H + D ) L ( 2 H + D ) L ( 3 H + 2 D ) L ( 4 H + 3 D ) L ( 5 H + 4 D ) L ) ( 17 )
And the solution for the projectile parameters P is found by inverting M and multiplying by Q, equation (18).
P=M −1 Q (18)
In practice, the time vector is measured based on the optical pulse provided to a computer from the fiber optic, such as 35 , associated with each of the six optical sensor layers of the FIG. 2 optical structure. Matrix M is then constructed based on the time vector. Then matrix M is inverted and matrix multiplied by Q for the solution P. The MATLAB code below, provides an exemplary solution embodying the above analysis for a simulated projectile solution.
Once P is known, then the projectile position can be computed for any time given, assuming straight-line constant velocity motion of the projectile. For a given time t_mark the position of the projectile can be computed per equations (1) through (3) with t_mark substituted for t. This would allow, for example, the determination of the origination point of a projectile if the initiation time was known. In some applications, the initiation time may be measured optically by using another optical fiber on the optical sensor structure shown in FIG. 2 to detect the light from the explosion. In other cases, such as for a gunshot, the initiation time must be computed from the knowledge that the sound and the projectile must travel the same distance to the optical sensor structure. If a sound transducer is located on plane 1 of the structure, the sound detection time t s is known. This time will likely occur after the projectile has already arrived at t=0. To compute the initiation time in this case, it is first necessary to compute the local sound speed, which is known to be a function of the air temperature and pressure. Assuming these measurements are available at the computer connected to the optical sensor structure, then the local sound speed S is known. Equation (19) then shows the equation for computing the bullet initiation time.
t _mark= St s /( S−√{square root over (V x 2 +V y 2 +V z 2 )}) (19)
This value can then be substituted for t in equations (1) through (3) to compute the spatial coordinates where the gunshot initiated relative to the optical sensor structure. It the sensor was not secured to a fixed position, it would also be necessary to have a record of the sensor location and orientation at the time of impact with respect to the battlespace coordinate system if the additional information was to be of use since the sensor computations of the projectile parameters are performed relative to the sensor coordinate system at the time of impact.
In some applications, fewer planes within the optical sensor structure may be used if less information is needed. For example, those skilled in the art will recognize that a four plane system would be sufficient to resolve V x , V y , and y 0 (assuming R=0) by employing an approach similar to that described above.
Handling Speed Attenuation
As a projectile passes through the sensor, it may experience speed attenuation as energy is transferred into the optical sensor structure. This results in a stretching of the time vector response. A method is described here for correcting for this phenomenon by processing the time vector prior to performing the computation of P. The resulting contracted time vector is the time vector that would have been measured if no speed attenuation had occurred. The velocity attenuation parameter R is defined as the ratio of the input speed to the output speed, for a single planar element, per equation (20). It is assumed that the inter-panel material slows the projectile by a negligible amount.
R =In_speed/Out_speed (20)
A recursive relationship then exists that allows for the computation of the stretched time vector from the unstretched time vector, equation (21), where the variable r corresponds to the stretched time vector.
r n =r n−1 +( t n −t n−1 ) R n−1 (21)
The solution to this recurrence relation provides a linear relationship between the contracted time vector and the stretched time vector that can be expressed in matrix form Kt=r. Since the time of penetration through the first panel is still equal to zero, only the times corresponding to the penetration of planes 2 through 7 are relevant for the computation of P; ie r 1 =t 1 =0. The full expression of this matrix equation is shown in equation (22).
( R 0 0 0 0 0 R - R 2 R 2 0 0 0 0 R - R 2 R 2 - R 3 R 3 0 0 0 R - R 2 R 2 - R 3 R 3 - R 4 R 4 0 0 R - R 2 R 2 - R 3 R 3 - R 4 R 4 - R 5 R 5 0 R - R 2 R 2 - R 3 R 3 - R 4 R 4 - R 5 R 5 - R 6 R 6 ) ( t 2 t 3 t 4 t 5 t 6 t 7 ) = ( r 2 r 3 r 4 r 5 r 6 r 7 ) ( 22 )
Note that if R=1, then K is equal to the identity matrix and the time vector is not stretched. In actual application, the measured time vector r must be contracted using the inverse transformation, equation (23) t=K −1 r prior to the computation of the parameter matrix P. R must be known to be able to accomplish this.
t=K −1 r (23)
A method is described for computing R and hence the matrix K from the original time vector. This is significant since R may vary from one projectile to the next. Even if R=1.001, the computed hit location and projectile velocity will have significant error if the actual speed attenuation is not taken into account. Since stretched time vectors can have computationally valid solutions for the projectile parameters, it is important that speed attenuation be known and the time vector is contracted prior to the computation of the projectile parameters. One way to build the measurement of R into a sensor structure in accordance with the present invention is to use a seventh plane ( 45 ) after the sixth sensor ( 70 ). The method here is to find the value of R that yields a contracted time vector and resulting V x that is consistent with the signal from the sensor in the seventh plane ( 45 ). The known spacing between the sixth and seventh sensors ( 70 and 45 ), HL, along with the temporal relationship of their responses yields an independent measure of V x at that point in the trajectory. Since the x component of the velocity must have the same attenuation R, it is possible to compute a single value of R that is consistent. Equation (24) expresses the nomenclature used in the following derivation and in the exemplary MATLAB code listing.
r ij =r i −r j (24)
Since the projectile must pass through six planes to get to the seventh, it experiences six speed reductions before it gets to the final, seventh sensor plane. This also holds true for each component of the velocity vector; therefore, an expression for V x is shown in equation (25).
HLR 6 =V x r 76 (25)
Similarly, if the projectile had not been retarded during passage, another expression can be written based on a contracted time when the projectile would have reached the sixth sensor ( 70 ), equation (26).
(5 H+ 4 D ) L=V x t 6 (26)
Solving both equations for V x and equating them yields equation (27), where L cancels out.
(5 H+ 4 D )/ t 6 =HR 6 /r 76 (27)
The recurrence relation, equation (21), can be used to develop an expression for t 6 in terms of the components of the stretched time vector, equation (28).
t 6 =R −5 r 65 +R −4 r 54 +R −3 r 43 +R −2 r 32 +R −1 r 21 (28)
Substituting equation (28) into equation (27) yields a 5 th order polynomial, equation (29) in R and the real solution is the R value as measured directly from the stretched time vector.
− Hr 21 R 5 −Hr 32 R 4 −Hr 43 R 3 −Hr 54 R 2 −Hr 65 R +(5 H+ 4 D ) r 76 =0 (29)
This has been validated in the exemplary MATLAB code listing. The independent measure of R by the use of a seventh sensor results in much greater accuracy and potentially can be correlated to the caliber of a projectile for a given sensor structure.
Scaling of Time Vectors
As would be expected, the scaling of a time vector by a scalar quantity W results in computed velocity components that are scaled by W −1 with impact position unchanged.
Exemplary MATLAB code Listing
% In a six sensor structure, five equations can be used by computing based
on t=0 when fragment hits front panel of MPOPS
% The equations directly yield fragment hit location at the first plane and
% velocity. Initial positions can then be computed based on initiation
% time. In real application, the initiation time may not be available.
% The following solution is not dependent on initiation time knowledge for
% The code checks if the temporal vector is ordered
% If the vector is ordered, the solution is found
% If not, an error message is issued
%
% The ratio of input speed/output speed = R
% A matrix K is used to contract the time vector prior to computing P
% If R=1 (ideal case), then K is the identity matrix
%
% The code allows the use of a seventh sensor to compute R
% from temporal measurements. The method requires the solution of a 5th
% order polynomial. By independently measuring
% R, the resulting projectile parameters are more accurate. Also the
% measurement of R provides additional information about how the projectile
% interacts with the optical sensor structure. This additional information
% might be sufficient to resolve weapon caliber or particle size. The
% seventh sensor is in a plane that is parallel to the sixth plane behind
% an additional spacer element. In this
% simulation, R is given to allow for computation of the retarded time
% vector. Then computation of R from the retarded vector proves that a
% measured retarded time vector will yield the same R directly. The
% derivation of the 5th order equation requiring solution is beyond the
% scope of this comment.
%
%
% Approach is to encode six planar equations in coordinate system (1st
% equation is trial, x0=0);
% Specify fragment parameters
% Compute plane penetration times, assuming plane 1 is penetrated at t=0
% Back-compute fragment parameters from penetration time vector
% Then compare back-computed parameters to original
% This allows for proof of concept since single panel test has already
% been performed
% This will allow testing the effect of deceleration and panel
% intolerances as well by interactively adjusting the forward computed
% penetration times and analyzing the effect on back-computed fragment
% parameters
%
% Panel design parameters
%
% H=interpanel gap/L
% D=percent depth change of wedge across panel width
% L=panel width=panel height
% Width is Y dimension
% Height is Z dimension
% Depth is X dimension
% d=thickness of an individual POPS element relative to L
% R=panel speed reducing ratio; Input speed/Output speed = R for a plane
% T=overall 6-DOF POPS thickness
%
clear all;
%
d=0.01;
L=1;
H=0.05;
D=0.15;
R=1.03;
T=(5*H+4*D)*L
%
% For now it is assumed that D is part of interchannel gap
% Later it may be necessary to upgrade code
%
% Fragment parameter vector has six components
%
% x_init,y_init,z_init,vx,vy,vz
%
% x_init,y_init,z_init is initial fragment position
% vx,vy,vz is fragment velocity vector
%
% units of x_init, y_init, and z_init are panel widths, relative to
coordinate system
% in Figure illustrating the 6-DOF POPS
%
% units of vx, vy, and vz are panel widths per millisecond
%
% The supplied parameters for the simulation are x_p1, y_p1, z_p1, t_mark,
vx, vy, and vz.
% x_p1, y_p1, and z_p1 are the x,y,z components of the hit point
% and t_mark is the time of interest of the fragment relative to impact
% time at p1. t_mark could be the initiation time or some other time of
interest for the fragment.
% A negative t_mark value corresponds to pre-impact position.
% A positive t_mark value corresponds to post-impact position.
% the vx, vy, and vz are the supplied fragment velocity components (vx < >
% 0). vx can be negative and impact times are still computed relative to impact
% at p1
%
x_p1=0;
y_p1=0.5;
z_p1=0.2;
t_mark=0;
vx=3;
vy=0.2;
vz=0.2;
%
% Compute the mark point based on the supplied simulation parameters
%
x_mark=x_p1+vx*t_mark;
y_mark=y_p1+vy*t_mark;
z_mark=z_p1+vz*t_mark;
Fin=[x_mark y_mark z_mark vx vy vz];
%
% Fsim is the starting point of the fragment at the MPOPS.
Fsim=[x_p1 y_p1 z_p1 vx vy vz];
%
% Computed penetration times for planes 1 through 6 assuming K=1.
%
t1=0;
t2=((H+D)*L−Fsim(1)−Fsim(2)*D)/(Fsim(4)+Fsim(5)*D);
t3=((2*H+D)*L−Fsim(1)+Fsim(2)*D)/(Fsim(4)−Fsim(5)*D);
t4=((3*H+3*D)*L−Fsim(1)−Fsim(3)*D)/(Fsim(4)+Fsim(6)*D);
t5=((4*H+3*D)*L−Fsim(1)+Fsim(3)*D)/(Fsim(4)−Fsim(6)*D);
t6=((5*H+4*D)*L−Fsim(1))/Fsim(4);
t7=((6*H+4*D)*L−Fsim(1))/Fsim(4);
t=[t1 t2 t3 t4 t5 t6 t7];
%
% Check that temporal vector is ordered
%
s=sort(t) %sorts in ascending order
r=fliplr(s) %flips left to right
% Perform computations iff temporal vector is ordered
if (all(t == s) | all(t == r))
%
% K is a matrix used to convert an unretarded time vector to a retarded
% time vector. It arises from a recurrence relation documented elsewhere
% K is the identity matrix iff R=1
%
K(1,:)=[R 0 0 0 0 0];
K(2,:)=[R−R{circumflex over ( )}2 R{circumflex over ( )}2 0 0 0 0];
K(3,:)=[R−R{circumflex over ( )}2 R{circumflex over ( )}2−R{circumflex over ( )}3 R{circumflex over ( )}3 0 0 0];
K(4,:)=[R−R{circumflex over ( )}2 R{circumflex over ( )}2−R{circumflex over ( )}3 R{circumflex over ( )}3−R{circumflex over ( )}4 R{circumflex over ( )}4 0 0];
K(5,:)=[R−R{circumflex over ( )}2 R{circumflex over ( )}2−R{circumflex over ( )}3 R{circumflex over ( )}3−R{circumflex over ( )}4 R{circumflex over ( )}4−R{circumflex over ( )}5 R{circumflex over ( )}5 0];
K(6,:)=[R−R{circumflex over ( )}2 R{circumflex over ( )}2−R{circumflex over ( )}3 R{circumflex over ( )}3−R{circumflex over ( )}4 R{circumflex over ( )}4−R{circumflex over ( )}5 R{circumflex over ( )}5−R{circumflex over ( )}6 R{circumflex over ( )}6];
%
%Generate the retarded time vector r
r = K*t(2:7)′;
% Contract the retarded time vector
tempt=inv(K)*r;
t=[0 tempt′];
% solve 5th order polynomial for R based on retarded time vector
r = [0 r′];
f=diff(r);
rpoly=[−H*f(1) −H*f(2) −H*f(3) −H*f(4) −H*f(5) (5*H+4*D)*f(6)];
solution = roots(rpoly);
R_comp=solution(5)
R
% Define the measurement matrix M and the depth vector Q
%
M(1,:)=[ D 0 t(2) D*t(2)
0
];
M(2,:)=[−D 0 t(3) −D*t(3)
0
];
M(3,:)=[ 0 D t(4) 0
D*t(4)
];
M(4,:)=[ 0 −D t(5) 0
−D*t(5)
];
M(5,:)=[ 0 0 t(6) 0
0
];
%
Q(1,1)=(H+D)*L;
Q(2,1)=(2*H+D)*L;
Q(3,1)=(3*H+3*D)*L;
Q(4,1)=(4*H+3*D)*L;
Q(5,1)=(5*H+4*D)*L;
%
% List times that fragment passes each plane, referenced to the first plane
% Compute the Fragment Vector Output Fout and Compare to the Fragment Vector
% Input Fin. The fragment parameters fp is the matrix product of the
inverse of M times D
% The first 2 components of fp are the computed Yhit and Zhit values and the
last 3 components are the
% computed fragment velocity components vx, vy, and vz.
% Fout is then computed to compare with Fin
%
t
r
P=inv(M)*Q; %fragment parameters
Hit=[0 P(1) P(2)]
Vel=[P(3) P(4) P(5)]
Inspeed=sqrt (P(3){circumflex over ( )}2+P(4){circumflex over ( )}2+P(5){circumflex over ( )}2)
Outspeed=Inspeed/R{circumflex over ( )}6
Fin
Fout=[t_mark*Vel(1) P(1)+t_mark*Vel(2) P(2)+t_mark*Vel(3) Vel(1) Vel(2)
Vel(3)]
save C:\MATLAB6p5\work\pops-output.txt t r Hit Inspeed Outspeed Fin Fout -
ASCII
else
disp(‘Scrambled time vector...multiple hit or data system error ’)
end
FIG. 5 is a schematic block diagram of a detection system embodying the present invention with a single optical fiber transmitting an optical signal from an optical sensor to a corresponding detector. In FIG. 5 , optical sensors embodying the present invention ( 75 , 80 , and 90 ) are connected via respective individual optical fibers ( 95 , 100 , and 105 ) to corresponding detectors ( 110 , 115 , and 120 ). The detectors 110 , 115 , and 120 can comprise, for example, photodetectors. The detectors 110 , 115 , and 120 can provide, for example, optoelectronic conversion of the optical signal detected on fiber optics 95 , 100 , and 105 . The detectors can also provide filtering and threshold detection of the electric signal generated by the detectors. While not shown in FIG. 5 , the detectors are operatively coupled to a computer that receives the time pulses provided by the optical sensors 75 , 80 , and 90 and detectors 110 , 115 , and 120 . These time pulses can be processed in accordance with the above equations and processing represented by the exemplary MATLAB code.
FIG. 6 is a schematic block diagram of a detection system embodying the present invention with a single optical fiber transmitting all optical sensor signals to a single detector. In FIG. 6 , optical sensors 125 , 130 , and 135 are connected to an N-to-1 optical connector, 155 , via short or local optical fibers 140 , 145 , and 150 . As is known to those skilled in the art, the N-to-1 optical connector, 155 , couples the light from each of the optical fibers, 140 , 145 , and 150 into the optical fiber 160 . The optical fiber 160 carries the optical signals to the detector 165 , which is typically located a safe distance from the event being monitored by the optical sensors, such as an explosion. The detector 165 can comprise, for example, a photodetector. The detector 165 can provide, for example, optoelectronic conversion of the optical signal detected on fiber optic 160 . The detector can also provide filtering and threshold detection of the electric signal generated by the detector. While not shown in FIG. 6 , the detector 165 is operatively coupled to a computer that receives the time pulses provided by the optical sensors 125 , 130 , and 135 and detector 165 . These time pulses can be processed in accordance with the above equations and processing represented by the exemplary MATLAB code.
FIG. 7 is a schematic block diagram of a detection system embodying the present invention with a single optical fiber transmitting all optical sensor signals to an array of detectors. The FIG. 7 system makes use of different light wavelengths provided by the optical sensors 170 , 175 , and 180 . The light provided by the optical sensors 170 , 175 , and 180 is coupled to an N-to-1 optical connector 200 via short or local fiber optics 185 , 190 , and 195 . As is known to those skilled in the art, the N-to-1 optical connector, 200 , couples the light from each of the fiber optics, 170 , 175 , and 180 into the fiber optic 240 . The optical fiber 240 carries the optical signals to the 1-to-N optical connector 205 , which is typically located a safe distance from the event being monitored by the optical sensors, such as an explosion. As is well known to those skilled in the art, the 1-to-N optical connector 205 , couples the different wavelengths of light to the corresponding fiber optics 210 , 215 , and 220 . The detectors 225 , 230 , and 235 detect the light carried by the corresponding fiber optics 210 , 215 , and 220 . As with FIGS. 5 and 6 , the detectors 225 , 230 , and 235 can comprise, for example, photodetectors that are sensitive to different wavelengths of light. The detectors 225 , 230 , and 235 can provide, for example, optoelectronic conversion of the optical signal detected on the corresponding fiber optics 210 , 125 , and 220 . The detector can also provide filtering and threshold detection of the electric signal generated by the detector. While not shown in FIG. 7 , the detectors 225 , 230 , and 235 are operatively coupled to a computer that receives the time pulses provided by the optical sensors 170 , 175 , and 180 and detectors 225 , 230 , and 235 . These time pulses can be processed in accordance with the above equations and processing represented by the exemplary MATLAB code.
|
A method of determining the path of a projectile comprises detecting multiple time of arrivals of the projectile in multiple intersecting planes and determining the path and speed of the projectile based on the multiple times of arrivals.
| 5
|
This application is a continuation of prior application, Ser. No. 07/793,093 filed Nov. 15, 1991, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a drive apparatus for a magnetic head used in an optomagnetic recording system and, more particularly, to a drive circuit apparatus for a magnetic head used in information recording of a magnetic field modulation scheme.
2. Related Background Art
In recent years, an optomagnetic recording apparatus has received a great deal of attention as a large-capacity external memory for a computer. An optical modulation scheme and a magnetic field modulation scheme are available as existing information recording schemes for the optomagnetic recording apparatus. Of these modulation schemes, the magnetic field modulation scheme has an advantage in that information recording can be performed without decreasing information transfer speed since an overwrite operation can be performed to simultaneously erase recorded information and write new information.
FIG. 1 is a schematic circuit diagram for driving a magnetic head used in the above magnetic field modulation scheme. In the magnetic field modulation scheme, as is known well, a light beam is emitted from a light source such as a semiconductor laser to an information recording medium to increase the temperature of an irradiated portion over a Curie point, and a magnetic field modulated in accordance with a recording signal is applied to this high-temperature portion, thereby changing the direction of magnetization in correspondence with the bit information. The circuit shown in FIG. 1 is an arrangement of a magnetic head using two coils L 1 and L 2 to generate a bias magnetic field. A switch element SW1 is connected to the coil L 1 through a resistor R 1 , and a switch element SW2 is connected to the coil L 2 through a resistor R 2 . A recording signal is supplied to the control terminal of the switch element SW1, and to the control terminal of the switch element SW2 through an inverter 100. As shown in FIG. 2, the coils L 1 and L 2 are wound around a magnetic core 101 serving as a magnetic field generation core in opposite directions. Terminals a to d of the coils in FIG. 2 correspond to those in FIG. 1. When a current is supplied from the terminal a to the terminal b, the coil L 1 generates a magnetic field having a given direction of polarization. When a current is supplied from the terminal c to the terminal d, the coil L 2 generates a magnetic field having a direction of polarization opposite to the given direction.
Assume that the recording signal is set at "1". Since the switch element SW1 is turned on and a current flows through the coil L 1 , a magnetic field is generated by the coil L 1 . At this time, since the switch element SW2 is kept off, no magnetic field is generated by the coil L 2 . On the other hand, when the recording signal is set at "0", the switch element SW1 is kept off, and the switch element SW2 is turned on. Therefore, a magnetic field is generated by the coil L 2 . The direction of the magnetic field generated by the coil L 1 is opposite to that of the magnetic field generated by the coil L 2 . Therefore, bias magnetic fields having different polarities corresponding to the levels of the recording signals can be generated.
FIG. 3 shows a magnetic head for generating a bias magnetic field by using one coil. In this arrangement, a current is switched and selectively supplied to a coil L 3 by using four switch elements SW1 to SW4. The recording signal is directly input to the control terminals of the switch elements SW2 and SW3, and to the switch elements SW1 and SW4 through an inverter 102. The coil L 3 is wound around a magnetic core 103, as shown in FIG. 4. By changing a current flow direction, the polarity of the generated magnetic field is changed. Terminals e and f of the coil shown in FIG. 4 correspond to those in FIG. 3.
In the above arrangement, for example, when the recording signal is set at "1", the switch elements SW2 and SW3 are turned on, and a current is supplied to the coil L 3 in a direction extending from the terminal f to the terminal e. On the other hand, when the recording signal is set at "0", the switch elements SW1 and SW4 are turned on, and a current is supplied to the coil L 3 in a direction from the terminal e to the terminal f. The direction of the magnetic field generated by the coil L 3 is changed, and therefore a bias magnetic field corresponding to the level of the recording signal can be generated.
In the magnetic field modulation scheme, the magnetic head is not used to reproduce information. It is, therefore, possible to maximize the distance between a recording medium and the magnetic head. An accident such as a head crash can be prevented. A magnetic field generated by the magnetic head must be larger than that generated by a magnetic recording apparatus such as an HDD. For this purpose, the coil must have a large inductance, and a current flowing through the coil must also be large. In order to always obtain a high-quality reproduced signal, a time (to be referred to as a switching time) required for reversing the magnetic field must be minimized.
In the conventional example described above, in order to satisfy this requirement, a power source voltage applied to the coil must be high. For this purpose, a new power source for the magnetic head is required in an optomagnetic recording apparatus, thus complicating the arrangement of the apparatus and increasing the size and cost of the apparatus.
SUMMARY OF THE INVENTION
The present invention has been made to eliminate the conventional problems described above, and has as its object to provide a simple magnetic head drive apparatus for driving a magnetic field generation coil at a high voltage without arranging a magnetic head high-voltage source.
In order to achieve the above object of the present invention, there is provided a magnetic head drive apparatus having at least one coil and operated so that a direction of a current supplied to the coil is controlled to generate a bias magnetic field corresponding to a recording signal applied to an information recording medium, comprising at least one capacitor (condenser) corresponding to each direction of a magnetic field generated upon supply of the coil current, wherein the capacitor stores a charge during a period in which a magnetic field having a direction corresponding to the capacitor is not generated, and the current is supplied from the charge stored in the capacitor when the magnetic field having the direction corresponding to the capacitor is generated.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a circuit diagram showing a conventional magnetic head drive apparatus;
FIG. 2 is a perspective view for explaining states of wound coils of a magnetic head used in the apparatus shown in FIG. 1;
FIG. 3 is a circuit diagram showing another conventional example;
FIG. 4 is a perspective view showing a state of a wound coil of a magnetic head in an apparatus shown in FIG. 3;
FIG. 5 is a circuit diagram of a magnetic head drive apparatus according to an embodiment of the present invention;
FIGS. 6A to 6L are timing charts showing an operation of the embodiment shown in FIG. 5;
FIG. 7 is a graph showing a discharge curve of a capacitor (condenser) used in the embodiment of FIG. 5;
FIG. 8 is an equivalent circuit diagram of a discharge circuit for the embodiment shown in FIG. 5;
FIG. 9 is a circuit diagram showing another embodiment of the present invention;
FIGS. 10A to 10K are timing charts showing an operation of the embodiment shown in FIG. 9;
FIG. 11 is a circuit diagram showing still another embodiment of the present invention;
FIGS. 12A to 12L are timing charts showing an operation of the embodiment shown in FIG. 11;
FIG. 13 is a circuit diagram showing still another embodiment of the present invention; and
FIGS. 14A to 14L are timing charts showing an operation of the embodiment shown in FIG. 13.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. FIG. 5 is a circuit diagram showing a drive circuit apparatus for a magnetic head according to an embodiment of the present invention. This embodiment exemplifies a drive apparatus using two coils as in FIGS. 1 and 2. The same parts as in FIG. 1 denote the same parts in FIG. 5, and a detailed description thereof will be omitted.
Referring to FIG. 5, capacitors C 1 and C 2 are arranged in correspondence with directions of magnetic fields, respectively. A current is supplied to each coil in accordance with a charge of a corresponding capacitor, as will be described later. A switch element SW3 is connected to one terminal of the capacitor C 1 , and a switch element SW5 is connected to the other terminal of the capacitor C 1 . The switch element SW3 is driven by the recording signal. While the coil L 1 does not generate a magnetic field, the switch element SW3 is connected to the power source side. However, while the coil L 1 generates a magnetic field, the switch element SW3 is connected to a resistor R 1 . A switch element SW5 is similarly driven by the recording signal. While the coil L 1 does not generate a magnetic field, the switch element SW5 is connected to ground. However, while the coil L 1 generates the magnetic field, the switch element SW5 is connected to the power source side.
Switch elements SW4 and SW6 are connected to the two terminals of the capacitor C 2 , respectively. The switch elements SW4 and SW6 are driven by a recording signal inverted by the inverter 100. The switch element SW4 is connected to the power source side while the coil L 2 does not generate a magnetic field. The switch element SW4 is connected to a resistor R 2 while the coil L 2 generates a magnetic field. The switch element SW6 is connected to ground while the coil L 2 does not generate a magnetic field. However, the switch element SW6 is connected to the power source side while the coil L 2 generates a magnetic field. Note that the switch elements SW1 and SW2 are similarly driven by the recording signals. When the recording signal is set at a high level, the switch elements SW1 and SW2 are turned on. When the recording signal is set at a low level, the switch elements SW1 and SW2 are turned off.
An operation of this apparatus will be described with reference to the timing charts shown in FIGS. 6A to 6L. FIG. 6A shows a recording signal of level "1". As shown in FIGS. 6B, 6D, and 6F, signals of high level are supplied to the switch elements SW1, SW3, and SW5, respectively. Under these conditions, the switch element SW1 is turned on, the switch element SW3 is connected to the resistor R 1 , and the switch element SW5 is connected to the power source side. That is, the respective switch elements are set in the state shown in FIG. 5. The capacitor C 1 is connected between the power source and the resistor R 1 . The capacitor C 1 is charged to a power source voltage V (to be described later). The coil L 1 receives a current from the current source including the capacitor C 1 .
While the recording signal is kept at "1", signals of low level obtained by inverting the recording signal by the inverter 100 are supplied to the switch elements SW2, SW4, and SW6, as shown in FIGS. 6C, 6E, and 6G. In this case, the respective switch elements are set in the state shown in FIG. 5. That is, the switch element SW2 is turned off, the switch element SW4 is connected to the power source side, and the switch element SW6 is connected to ground. The capacitor C 2 is connected between the power source and ground. During this period, the capacitor C 2 is charged to the power source voltage V. The capacitor C 1 is charged to the power source voltage V in the same operation as described above, thereby driving the coil L 1 , as described above. At this time, a voltage (i.e., a voltage at the negative terminal of the resistor R 1 ) at a point g is 2V as a sum of the power source voltage V and the charge voltage V of the capacitor C 1 , as shown in FIG. 6H. A voltage twice the power source voltage V is applied to the resistor R 1 and the coil L 1 . A current from the current source including the charge of the capacitor C 1 is supplied to the coil L 1 . The current of the coil L 1 is shown in FIG. 6J. A magnetic field +H is generated by the coil L 1 by the current of FIG. 6J, as shown in FIG. 6L. The generated magnetic field is applied to an optomagnetic information recording medium such as an optomagnetic disk (not shown). The information recording medium is also irradiated with a laser beam having a predetermined intensity. By the light radiation and the application of the bias magnetic field, bit information corresponding to the recording signal of level "1" is recorded in the optomagnetic disk.
When the recording signal goes to "0" level, the switch element SW1 is turned off, and the switch element SW2 is turned on. In synchronism with the OFF operation of the switch element SW1, the switch element SW3 is connected to the power source side, and the switch element SW5 is connected to ground. Charging of the capacitor C 1 is started again. Similarly, in synchronism with the ON operation of the switch element SW2, the switch element SW4 is connected to the resistor R 2 , and the switch element SW6 is connected to the power source side. In this case, the voltage (i.e., the voltage at the negative terminal of the resistor R 2 ) at the point h is twice the voltage of the power source voltage, as shown in FIG. 6I, because the capacitor C 2 has already been charged to the power source voltage. The coil L 2 is driven by the voltage twice the power source voltage and receives a current shown in FIG. 6K. As shown in FIG. 6L, a magnetic field -H is generated by the coil L 1 . When this bias magnetic field is applied to the information recording medium, bit information corresponding to the recording signal of level "0" is recorded. In this manner, the operations of the switch elements are controlled in accordance with the levels of the recording signals. Each coil receives the current corresponding to the voltage twice the power source voltage.
As described above, according to this embodiment, the capacitors C 1 and C 2 are charged while the corresponding coils do not generate magnetic fields. When the corresponding coils generate the magnetic fields, the charges of the capacitors are used to supply currents to these coils. Therefore, the voltage applied to each coil is the sum of the power source voltage and the charge voltage of the capacitor. That is, the coil is driven at the voltage twice the power source voltage. For this reason, even if the coil has a large inductance, the switching time (rise time of the coil current) of the coil can be shortened. In this case, if the power source voltage is equal to that used in a conventional arrangement, the switching time can be reduced into 1/2. A new magnetic head high-voltage source need not be arranged. The power source voltage can be doubled by a simple apparatus including the capacitors and the switch elements described above.
In the embodiment of FIG. 5, potentials at the points g and h are lowered as a function of time. Decreases in potentials are shown in FIG. 7. An equivalent circuit during capacitor discharge is shown in FIG. 8. Referring to FIG. 8, R corresponds to R 1 and R 2 , L corresponds to L 1 and L 2 , and C corresponds to C 1 and C 2 . An initial charge stored in the capacitor is defined as Q, and an initial potential is defined as V D .
Referring to FIG. 7, a time T 0 required to lower the potential of the capacitor C by 10% for R=0 is given as follows: ##EQU1## That is, unless the duration of the recording signal of level "0" or "1" is longer than T 0 , an effective voltage cannot be applied to the coil. A longest duration T (to be referred to as a maximum magnetic field reversal time hereinafter) of the recording signal is given as follows: ##EQU2## The capacitor C must satisfy the following condition:
C>T.sup.2 /1000×L (3)
FIG. 9 shows another embodiment of the present invention, exemplifying a magnetic head apparatus for generating a bias magnetic field by using one coil as in FIG. 3. The same reference numerals as in FIGS. 3 and 5 denote the same parts in FIG. 9, and a detailed description thereof will be omitted.
Arrangements of capacitors C 1 and C 2 and switch elements SW3 to SW6 connected to their two terminals in FIG. 9 are the same as those in FIG. 5. The switches SW1 and SW2 are symmetrical with those in FIG. 5 about a vertical line. In this embodiment, the switch elements SW3 and SW5 are operated in synchronism with the switch element SW2, and the switch elements SW4 and SW6 are operated in synchronism with the operation of the switch element SW1 in accordance with the recording signals. The switch elements are switched to control charging and discharging of the capacitors C 1 and C 2 . The coil L 3 is driven at a voltage twice the power source voltage in the same manner as in the above embodiment.
FIGS. 10A to 10K are timing charts showing a detailed operation of the embodiment shown in FIG. 9. FIG. 10A shows a recording signal, and FIGS. 10B to 10G are voltage signals respectively supplied to the switch elements SW1 to SW6. When the recording signal is set at level "1", the switch element SW2 is turned on, the switch element SW3 is connected to the power source side, and the switch element SW5 is connected to ground, thereby obtaining the state in FIG. 9. The capacitor C 1 is charged and is ready to discharge the charge to the coil L 3 . On the other hand, the switch element SW1 is kept off, the switch element SW4 is connected to a resistor R 2 , and the switch element SW6 is connected to the power source side, thereby obtaining a state shown in FIG. 9. A current path from the power source to ground in an order of the capacitor C 2 , the coil L 3 , and the switch element SW2 is formed. A current is supplied to the coil L 3 , as shown in FIG. 10J. In this case, the capacitor C 2 is charged to almost the power source voltage, and a voltage at a point j is twice the power source voltage, as shown in FIG. 10H. In this embodiment, therefore, as described above, the coil is driven at a voltage twice the power source voltage. As a result, a magnetic field shown in FIG. 10K is generated by the coil L 3 . When this field is applied to the information recording medium, bit information corresponding to the recording signal of level "1" is recorded.
When the recording signal goes to level "0", the switch element SW2 is turned off, and the switch element SW1 is turned on. The switch element SW3 is connected to the resistor R 1 , and the switch element SW5 is connected to the power source side in synchronism with these operations of the switch elements SW1 and SW2. In addition, the switch element SW4 is connected to the resistor R 2 , and the switch element SW6 is connected to ground. The capacitor C 2 is charged again, and the capacitor C 1 is discharged. The charge of the capacitor C 1 is supplied to the coil L 3 . In this case, a potential at a point i of FIG. 9 is twice the power source voltage, as shown in FIG. 10I. A current flows through the coil L 3 in an opposite direction, as shown in FIG. 10J. The direction of the magnetic field is also opposite, as shown in FIG. 10K. The generated magnetic field is applied to the recording medium, and bit information corresponding to the recording signal of level "0" is recorded. As described above, according to this embodiment, the capacitor is charged, and the charge is supplied to the coil. The coil can be driven at a voltage twice the power source voltage, thereby obtaining the same effect as in the embodiment of FIG. 5.
FIG. 11 is a circuit diagram showing still another object of the present invention. This embodiment is a modification of the embodiment of FIG. 5. The embodiment of FIG. 11 has a characteristic feature in that currents are supplied from the capacitors to coils L 1 and L 2 only during rise times of the currents. The same reference numerals as in FIG. 5 denote the same parts in FIG. 11.
Referring to FIG. 11, a drive apparatus includes the coils L 1 and L 2 serving as bias magnetic field generating coils, coil drive capacitors C 1 and C 2 , and switch elements SW1 and SW2 operated by recording signals. The functions of the above components are the same as those in the embodiment of FIG. 5. Switch elements SW2 to SW6 control charging/discharging of the capacitors as in the previous embodiments. These switch elements are controlled by a timing control circuit (not shown) to supply capacitor charges to the corresponding coils only during rise times of the currents. In this embodiment, a voltage of a power source for charging the capacitors C 1 and C 2 is defined as V 1 , a power source voltage for the coils L 1 and L 2 is V 2 , and the voltages V 1 and V 2 satisfy the condition V 1 >V 2 . The drive apparatus also includes reverse blocking diodes D 1 to D 4 .
FIGS. 12A to 12L are timing charts showing an operation of the above embodiment. FIG. 12A shows a recording signal, FIG. 12B shows a signal supplied to the switch element SW1, and FIG. 12C shows a signal supplied to the switch element SW2. When the recording signal is set at level "1", the switch element SW1 is ON, and the switch element SW2 is OFF. FIGS. 12D to 12G show signals respectively supplied to the switch elements SW3 to SW6. Each of these signals has a pulse width t. This pulse width t is set almost equal to the current rise time of each of the coils L 1 and L 2 . When the recording signal is set at level "1", the switch element SW1 is turned on, and the switch elements SW3 and SW4 are set in a state shown in FIG. 11. At this time, the switch element SW2 is turned off, and the switch elements SW4 and SW6 are set in a state shown in FIG. 11. The charge of the capacitor C 1 is supplied to the coil L 1 , and a current is supplied to the coil L 1 , as shown in FIG. 12J. In this case, a voltage at a point a in FIG. 11 is 2V 1 , which is twice the power source voltage V 1 , as shown in FIG. 12H. A time required to double the voltage is almost equal to the rise time of the current flowing through the coil L 1 . Therefore, a high voltage can be applied to the coil L 1 during only the rise time of the current. In addition, no resistance is present in a current path, and the current rise time for the coil L 1 can be greatly shortened. When the time t has elapsed, the power source voltage V 2 is applied to the coil L 1 .
During this period, the capacitor C 2 is charged to the power source voltage V 1 to prepare for the supply of the current to the coil L 2 . When the recording signal goes to level "0", the switch element SW2 is turned on, the switch elements SW4 and SW6 are connected in directions opposite to those shown in FIG. 11, and a current is supplied from the capacitor C 2 to the coil L 2 . At this time, a voltage at a point c is doubled to 2V 1 during the time t, as shown in FIG. 12I. The coil L 2 is driven at the voltage twice the power source voltage during the rise time of the current, and FIG. 12K shows the current of the coil L 2 at this time. When the time t has elapsed, the power source voltage V 2 is applied to the coil L 2 . A high voltage is similarly applied to the coil L 2 during only the current rise time, thereby greatly shortening the current rise time. Meanwhile, the capacitor C 1 is charged again to prepare for the supply of the current to the coil L 1 . FIG. 12L shows the magnetic field generated by the coil L 1 or L 2 . This generated magnetic field is applied to the information recording medium, and pieces of bit information corresponding to the recording signals of levels "1" and "0" are recorded.
In this embodiment, a high voltage is applied to each of the coils L 1 and L 2 during only the current rise time, and no resistance is present in the current supply path. The current rise time of each coil can be greatly shortened as compared with conventional cases. When the charge of each capacitor is to be supplied to the corresponding coil, the energy stored in the capacitor can be effectively used due to the absence of the resistance in the current path, thereby reducing the total power consumption.
FIG. 13 shows still another embodiment of the present invention. This embodiment is a modification of FIG. 11. Only one capacitor is used for each coil in the embodiment of FIG. 11. However, in the embodiment of FIG. 13, two capacitors are used for each coil to supply a current thereto.
A capacitor C 3 is connected in series with a capacitor C 1 , and a capacitor C 4 is connected in series with a capacitor C 2 . During current supply to each coil, each pair of capacitors are connected in series with each other, so that a voltage three times the power source voltage is applied to each coil. The capacitors C 1 and C 3 and the capacitors C 2 and C 4 are charged parallel to each other. Charging/discharging of the capacitor C 3 is controlled by switch elements SW7 and SW9. Charging/discharging of the capacitor C 4 is controlled by switch elements SW8 and SW10. A relationship between power source voltages V 1 and V 2 satisfies the condition V 1 >V 2 . Other arrangements in FIG. 13 are the same as those in FIG. 11.
FIGS. 14A to 14L are timing charts showing an operation of the embodiment in FIG. 13. FIG. 14A shows a recording signal, and FIGS. 14B and 14C show signals respectively supplied to the switch elements SW1 and SW2, as in the embodiment of FIG. 11. Signals shown in FIGS. 14D to 14G are supplied to switch elements SW3 to SW6 and the switch elements SW7 to SW10, all of which serve to control charging/discharging of the corresponding capacitors. In this embodiment, the switch elements SW3 and SW7 and the switch elements SW5 and SW9 are simultaneously switched. The switch elements SW4 and SW8, and the switch elements SW6 and SW10 are simultaneously switched. When the recording signal is set at level "1", the switch element SW1 is ON, and the switch SW2 is OFF. In this case, the switch elements SW3 and SW5 and the switch elements SW7 and SW9 are set in a state shown in FIG. 13. In this state, the capacitors C 1 and C 3 are connected in series with each other. This connecting time is set equal to a time t as the current rise time of the coil L 1 in the same manner as in FIG. 11.
The capacitors C 1 and C 3 are charged to the power source voltage V 1 each. A voltage at a point a is three times the power source voltage V 1 , as shown in FIG. 14H. In this embodiment, the voltage three times the power source voltage can be applied during the current rise time of the coil L 1 . The current rise time of the coil L 1 can be further shortened. When the time t has elapsed, the power source voltage V 2 is applied to the coil L 1 . In this period, the switch elements SW4 and SW8 and the switch elements SW6 and SW10 for controlling the capacitors C 2 and C 4 are set in the state shown in FIG. 13. The capacitors C 2 and C 4 are charged with the power source voltage V 1 in a parallel manner.
When the recording signal is set at level "0", the switch element SW1 is turned off, and the switch element SW2 is turned on. The capacitor control switches SW3 to SW10 are connected in a state opposite to that shown in FIG. 13. In this case, the capacitors C 2 and C 4 are connected in series with each other. The charges of the capacitors C 2 and C 4 cause a current to flow in the coil L 2 . FIG. 14I shows a voltage at a point c. During the time t, the voltage is three times the power source voltage. During the current rise time of the coil L 2 , the voltage three times the power source voltage is applied, so that the current rise time of the coil L 2 is shortened. Meanwhile,, the capacitors C 1 and C 3 are charged again to prepare for the next current supply cycle. FIG. 14J shows the current of the coil L 1 , FIG. 14H shows the current of the coil L 2 , and FIG. 14L shows the generated magnetic field.
As described above, according to this embodiment, since a current is supplied to each coil by using a pair of capacitors, a voltage three times the power source voltage can be applied to the coil during the current rise time. The current rise time of the coil can be shortened, as compared with the embodiment shown in FIG. 11. In the embodiment shown in FIG. 13, each coil is driven using a pair of capacitors. However, a coil can be driven using three or more series-connected capacitors. In the embodiments of FIGS. 5 and 9, it is possible to supply a current to a coil by using a plurality of capacitors.
According to the present invention, as has been described above, since the bias magnetic field generation coil is driven by utilizing charge stored in the capacitor, a voltage including the charge voltage of the capacitor and higher than the power source voltage can be applied to the coil. Therefore, a large current is supplied to the coil. Even if an inductance of a coil is large, the switching time of the coil can be shortened by an increase in voltage applied thereto. In addition, a high power source for a coil need not be arranged. The above effects can be obtained by a simple apparatus including a capacitor and a switching element.
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A drive circuit apparatus for driving a magnetic head includes a magnetic core, a coil wound around the magnetic core, and a unit for supplying current to the coil. The supplying unit includes first and second capacitors and a charging unit such that the second capacitor is charged while the current is supplied to the coil by a charge stored in the first capacitor.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] Not applicable.
INCORPORATION-BY-REFERENCE OF MATERIALS SUBMITTED ON A COMPACT DISC
[0004] Not applicable.
BACKGROUND OF THE INVENTION
[0005] 1. Field of the Invention
[0006] The present patent application for industrial invention relates to a display, in particular a refrigerated display used to display food products. Although in the following description reference is made to a refrigerated display, the present invention is extended to any type of display.
[0007] 2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 37 CFR 1.98.
[0008] Various types of refrigerated displays are known on the market to display food products. FIG. 1 is a perspective view of a display ( 100 ) comprising a box frame ( 1 ) that comprises a compartment ( 2 ) intended to contain foods in general and beverages to be refrigerated, and an opening ( 4 ) that provides access to said compartment ( 2 ). In correspondence of said opening ( 4 ) the display ( 100 ) comprises an upper crosspiece ( 12 ) and a lower crosspiece ( 13 ).
[0009] The display ( 100 ) comprises two pairs (C) of revolving door panels ( 3 ) intended to close the opening ( 4 ) of the box frame ( 1 ).
[0010] Each door panel ( 3 ) can be disposed in a plurality of positions comprised between an opening position, wherein the pairs (C) of door panels ( 3 ) provide access to the compartment ( 2 ), and a closing position, wherein the access to the compartment ( 2 ) is prohibited to preserve the internal temperature.
[0011] The pairs (C) of door panels ( 3 ) open towards the interior of the compartment ( 2 ) in such way that, in opening position, the door panels ( 3 ) are contained inside the compartment ( 2 ).
[0012] With reference to FIG. 2 , which is a detailed view of one of the door panels ( 3 ) of one of said pairs (C) of door panels ( 3 ), each door panel ( 3 ) has a rectangular configuration and comprises:
a first side ( 3 d ) directed towards the interior of the compartment ( 2 ) when the door panel ( 3 ) is in closing position, a second side ( 3 e ) directed towards the outside of the compartment ( 2 ) when the door panel ( 3 ) is in closing position, two vertical lateral edges ( 3 a ) in parallel position, an upper horizontal edge ( 3 b ) disposed in proximity to the upper crosspiece ( 12 ), a lower horizontal edge ( 3 c ) disposed in proximity to the lower crosspiece ( 13 ).
[0018] The two door panels ( 3 ) of each pair (C) are disposed in side by side position and hinged in correspondence of the opposite vertical edges ( 3 a ) in such a way to rotate in opposite direction around corresponding vertical axes of rotation (Y-Y).
[0019] Advantageously, said pairs (C) of door panels ( 3 ) are partially or fully transparent in order to allow the user to see the products contained in the compartment ( 2 ).
[0020] The display ( 100 ) comprises hinging means ( 7 a ) to hinge the door panels ( 3 ) to said box frame ( 1 ).
[0021] The hinging means ( 7 a ) are configured in such way that the door panels ( 3 ) rotate around the corresponding vertical axes (Y-Y) of rotation.
[0022] The hinging means ( 7 a ) comprise:
an upper pin ( 73 ) that connects the door panel ( 3 ) to the upper crosspiece ( 12 ) of the box frame ( 1 ), and an idle lower pin ( 70 ) that connects the door panel ( 3 ) to the lower crosspiece ( 13 ) of the box frame ( 1 ).
[0025] With reference to FIG. 1 , the display ( 100 ) comprises an actuation means (M 1 ) for the automatic actuation of each door panel ( 3 ).
[0026] The actuation means (M 1 ) actuate the hinging means ( 7 a ) to make the door panel ( 3 ) rotate around the axis of rotation (Y-Y); in particular, the actuation means (M 1 ) are connected to the upper pin ( 73 ) of the hinging means of each door panel ( 3 ).
[0027] The upper pin ( 73 ) of the hinging means of a door panel ( 3 ) is actuated by the actuation means (M 1 ) and permits the rotation of the door panel ( 3 ).
[0028] The display ( 100 ) comprises detection means (R) to detect the presence of the user in proximity to the door panel ( 3 ) and/or inside the compartment ( 2 ) of the display ( 100 ), as shown in FIG. 1 .
[0029] The detection means (R) detect the presence of the user in proximity to one of the door panels ( 3 ) and send an activation signal, either directly or with a manual command, to the actuation means (M 1 ) that consist in a set of electric motors, each of them comprising a drive shaft coupled to one of the upper pins ( 73 ) of the door panels ( 3 ); in view of the above, when a motor is actuated, the corresponding door panel ( 3 ) is rotated in the opening or closing direction according to the direction of rotation of the electric motor.
[0030] In case of a refrigerated display, the display ( 100 ) comprises means for cold air circulation, which are not shown in the figure, intended to refrigerate the interior of said compartment ( 2 ).
[0031] A first drawback of this type of known displays ( 100 ) consists in the difficulty encountered in synchronizing the simultaneous movement of the two door panels ( 3 ) of each pair (C) of door panels ( 3 ); such a drawback occurs when the two electric motors that are used to operate each pair (C) of door panels ( 3 ) are not perfectly synchronized originally or lose synchronization during operation.
[0032] A second drawback is related to the high purchasing and maintenance cost of the set of electric motors provided for the automatic actuation of the door panels ( 3 ).
[0033] Moreover, the door panels ( 3 ) are difficult to dismount given the fact that the upper pin ( 73 ) of each door panel ( 3 ) is firmly connected with the drive shaft of one of the electric motors.
[0034] An additional drawback of this kind of known displays ( 100 ) is related to the fact that the door panels ( 3 ) cannot be actuated if the actuation means (M 1 ) are blocked.
[0035] The blocking of the electric motors can be caused either by a breakdown or a blackout.
[0036] Moreover, the door panels ( 3 ) are joined to the actuation means (M 1 ) and consequently the incorrect operation of the actuation means (M 1 ) would cause an incorrect actuation of the door panels ( 3 ).
[0037] Finally, another drawback is related to the fact that, in case of malfunctioning of the detection means (R), they would not identify the presence of the user's hand inside the compartment ( 2 ) and would consequently send an activation signal to the actuation means (M 1 ) to enable the closing of the door panels ( 3 ), with the risk of injuring the user's hand by tightening it between the pair of door panels ( 3 ) automatically actuated in closing direction.
[0038] On the contrary, in case of malfunctioning, said detection means (R) would not identify the presence of a user in front of the door panels ( 3 ) and, consequently, would not send an activation signal to the actuation means (M 1 ) to enable the opening of the door panels ( 3 ), thus preventing the user from accessing the compartment ( 2 ) and picking the desired product.
[0039] The main purpose of the present invention is to remedy the drawbacks of the prior art as described above by disclosing an improved display provided with actuation means for the pairs of door panels, which are able to solve the aforementioned problems with reference to the synchronization of the opening/closing movement of the door panels of each pair of door panels.
[0040] The second purpose of the present invention is to devise an improved display that is capable of operating also in case of breakdown or malfunctioning of the actuation means and of the detection means.
[0041] The third purpose of the present invention is to devise an improved display that, in addition to achieving the aforementioned purposes, is provided with actuation means for the automatic actuation of the door panels, which is able to avoid detrimental effects for the safety of the users or of the operators in charge of loading and maintaining the display of the invention.
BRIEF SUMMARY OF THE INVENTION
[0042] These purposes are achieved in accordance to the invention with the characteristics of the independent claim 1 .
[0043] Advantageous embodiments of the invention will appear from the dependent claims.
[0044] The display of the invention comprises:
a box frame that comprises a compartment and an opening to access said compartment; at least one pair of revolving door panels, adapted to close at least partially said at least one opening of the box frame; each door panel of said at least one pair of door panels being connected to the box frame, in such manner to be disposed in a closing position and in an opening position; hinging means to hinge said each door panel to said box frame; said hinging means being configured in such manner that said door panel rotates around an axis of rotation, being disposed in an opening position and in closing position; said hinging means comprising a pivoting pin used to connect and hinge each door panel to the box frame; actuation means that actuate said hinging means in order to rotate each door panel around said axis of rotation.
[0049] The peculiarity of said display consists in the fact that said actuation means comprise:
an electric motor; a slide that is actuated by said electric motor and makes alternate rectilinear travels; a connecting rod connected to said slide; two cranks, of which one of said two cranks is connected to said connecting rod; each crank being connected to the first pivoting pin of one of said door panels of said at least one pair of door panels, in such way that each door panel is connected with only one crank; a transmission lever that connects said at least two cranks.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0055] For purposes of clarity, the description of the improved display of the invention continues with reference to the attached technical drawings, which only have an illustrative, not limiting value, wherein:
[0056] FIG. 1 is a perspective view of a display according to the prior art;
[0057] FIG. 2 is a perspective view of a door panel of the display of FIG. 1 ;
[0058] FIG. 3 is an axonometric view of the display of the invention, wherein the door panels are in partially opening position;
[0059] FIGS. 4, 5 and 6 are axonometric views of the actuation means and the door panels of the display according to the present invention in three different actuation steps of the door panels; in FIG. 4 the door panels are in closing position, in FIG. 5 the door panels are in partial opening position and in FIG. 6 the doors are in complete opening position;
[0060] FIG. 5 a is a top view of the actuation means of the door panels in the position shown in FIG. 5 ;
[0061] FIG. 7 is an axonometric view of the door panel, of the fast coupling/uncoupling means, of the hinging means and of the movement component according to a first embodiment of the invention;
[0062] FIG. 8 is an axonometric view of the door panel, of the fast coupling/uncoupling means, of the hinging means and of the movement component to a second embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0063] In the following description the parts that are identical or correspond to the parts described above with reference to the prior art are identified with the same numerals, omitting their detailed description.
[0064] With reference to FIGS. 3 to 8 , a display ( 200 ) according to the invention is disclosed, which operates as a refrigerator, comprising hinging means to hinge the door panels ( 3 ) to said box frame ( 1 ).
[0065] With reference to FIG. 7 , the display ( 200 ) comprises a movement component ( 61 ) that is coupled with the door panel ( 3 ) to actuate the door panel ( 3 ).
[0066] The movement component ( 61 ) is a bar intended to be stopped against an upper part of the door panel ( 3 ).
[0067] The movement component ( 61 ) has an overturned “L” cross section, comprising:
a vertical portion ( 61 b ) comprising an abutting side ( 612 ) that is directed towards the door panel ( 3 ) when the door panel ( 3 ) is connected to said movement component ( 61 ); a horizontal portion ( 61 a ) that extends above the upper edge ( 3 b ) of the door panel ( 3 ) when the door panel ( 3 ) is connected to said movement component ( 61 ).
[0070] Said horizontal portion ( 61 a ) comprises a lower side ( 611 ) directed towards the upper edge ( 3 b ) of the door panel ( 3 ). The horizontal portion ( 61 a ) and the vertical portion ( 61 b ) are connected perpendicularly.
[0071] The display ( 200 ) comprises fast coupling/uncoupling means ( 92 , 93 ) to provide the fast coupling of the movement component ( 61 ) with the door panel ( 3 ) in order to actuate the door panel ( 3 ) by means of the actuation means (M), as well as the fast uncoupling of said movement component ( 61 ) from the door panel ( 3 ) in order to actuate said door panel ( 3 ) manually independently from the actuation means (M).
[0072] According to a preferred embodiment of the invention, said fast coupling/uncoupling means ( 92 , 93 ) comprise magnetic retention means ( 92 , 93 ) arranged on the door panel ( 3 ) and/or on the movement component ( 61 ).
[0073] In particular, said magnetic retention means ( 92 , 93 ) advantageously comprise a magnet ( 92 ) fixed on the abutting side ( 612 ) of the vertical portion ( 61 b ) of the movement component ( 61 ), and a metal bracket ( 93 ) that is fixed on the first side ( 3 d ) of the door panel ( 3 ), in proximity to the upper edge ( 3 b ) of the door panel and cooperates with said magnet ( 92 ).
[0074] More precisely, when the door panel ( 3 ) is in closing position, said magnet ( 92 ) is stopped against said metal bracket ( 93 ).
[0075] Advantageously, said metal bracket ( 93 ) is fixed on the first side ( 3 d ) of the door panel ( 3 ) with screws (V).
[0076] According to an alternative embodiment of the invention, which is not shown in the attached figures, said fast coupling/uncoupling means ( 92 , 93 ) can comprise a pair of magnets, of which a first magnet is fixed on the first side ( 3 d ) of the door panel ( 3 ), in proximity to the upper edge ( 3 b ) of the door panel ( 3 ), and a second magnet is fixed on the abutting side ( 612 ) of the movement component ( 61 ).
[0077] As shown in FIG. 7 , the hinging means are configured in such manner that the door panels ( 3 ) rotate around an axis of rotation (Y-Y).
[0078] The hinging means comprise:
a first pivoting pin ( 71 ) of the door panel ( 3 ) connected to the movement component ( 61 ); a second pivoting pin ( 70 ) fixed to the door panel ( 3 ) in coaxial position to the first pivoting pin ( 71 ) and rotating in idle in a hole obtained on the lower crosspiece ( 13 ).
[0081] Said first pivoting pin ( 71 ) comprises a first section ( 71 a ) connected to said actuation means (M) and to said movement component ( 61 ), and a second section ( 71 b ) revolvingly inserted in idle inside a hole (F) provided on the door panel ( 3 ).
[0082] More precisely, the axis of rotation (Y-Y) of each door panel ( 3 ) is advantageously vertical and the first pivoting ( 71 ) of each door panel ( 3 ) has the first section ( 71 a ) disposed above the horizontal portion ( 61 a ) of the movement component ( 61 ) and the second section ( 71 b ) interposed between the upper edge ( 3 b ) of the door panel and the horizontal portion ( 61 a ) of the movement component ( 61 ).
[0083] With reference to FIGS. 4, 5 and 6 , the display ( 200 ) of the invention comprises actuation means (M) that actuate the hinging means to make each door panel ( 3 ) rotate around the axis of rotation (Y-Y).
[0084] The actuation means (M) simultaneously actuate all the door panels ( 3 ), are positioned on the upper crosspiece ( 12 ) of the box frame ( 1 ) and are connected to the first pivoting pin ( 71 ) of each door panel ( 3 ).
[0085] The actuation means (M) are seen from above in FIG. 5 a , being all disposed above the upper crosspiece ( 12 ) of the box frame ( 1 ); in FIG. 5 a the arrows indicate the movement made by all the parts of the actuation means (M).
[0086] With reference to FIG. 5 a , said actuation means comprise:
an electric motor ( 81 ); a slide ( 83 ) that is actuated by the electric motor ( 81 ) and makes alternate rectilinear travels; a first connecting rod ( 84 a ) connected to said slide ( 83 ); a second connecting rod ( 84 b ) connected to said slide ( 83 ); a first transmission lever ( 85 a ) connected to said first connecting rod ( 84 a ); a second transmission lever ( 85 b ) connected to said second connecting rod ( 84 b ); a set of first cranks ( 86 a ) specifically, three first cranks ( 86 a ) mutually connected by means of said first transmission lever ( 85 a ); a first crank ( 86 a ) of said first cranks ( 86 a ) being connected to said first connecting rod ( 84 a ); each first crank ( 86 a ) being connected to said first pivoting pin ( 71 ) of one of the door panels ( 3 ); all the door panels ( 3 ) being connected by means of the first pivoting pins ( 71 ) to the set of first cranks ( 86 a ), rotating in the same opening direction, specifically in clockwise direction, as shown in FIG. 5 a a set of second cranks ( 86 b ) specifically three second cranks ( 86 b ) mutually connected by said second transmission lever ( 85 b ); a second crank ( 86 b ) of said second cranks ( 86 b ) being connected to said second connecting rod ( 84 b ); each second crank ( 86 b ) being connected to the first pivoting pin ( 71 ) of one of the door panels ( 3 ); all the door panels ( 3 ) being connected by means of the first pivoting pins ( 71 ) to the set of second cranks ( 86 b ) rotating in the same opening direction, specifically in anticlockwise direction, as shown in FIG. 5 a.
[0095] The operation of the actuation means (M) is as follows:
the rectilinear movement of the slide ( 83 ) is transmitted by means of the first ( 84 a ) and the second connecting rod ( 84 b ) to a first ( 86 a ) and a second crank ( 86 b ); said first ( 86 a ) and second crank ( 86 b ) transmit the motion respectively to the set of first cranks ( 86 a ) and to the set of second cranks ( 86 b ) by means of the first ( 85 a ) and the second transmission lever ( 85 b ).
[0098] The operation of the entire display ( 200 ) of the invention is described below, with reference to FIGS. 4, 5 and 6 , to provide a better understanding of the structure of the display according to the invention and appreciate its advantages.
[0099] As soon as a user stands in front of the display:
the detection means (R) of the display ( 200 ) of the invention detect the presence of the user in proximity to the door panel ( 3 ) of the display ( 200 ) and send an activation signal to the electric motor ( 81 ); the electric motor ( 81 ) actuates the slide ( 83 ); by means of the aforementioned kinematic mechanism composed of connecting rods ( 84 a, 84 b ), cranks ( 86 a, 86 b ) and transmission levers ( 85 a, 85 b ), the slide ( 83 ) actuates all the first pivoting pins ( 71 ); by rotating, all the first pivoting pins ( 71 ) of the door panels ( 3 ) actuate all the movement components ( 61 ); all the movement components ( 61 ) actuate all the door panels ( 3 ).
[0105] A first advantage can be found when one of the following problems occurs:
incorrect operation of the actuation means (M); blocking of the actuation means (M); breakdown or malfunctioning of the detection means ®.
[0109] In the past, the door panels ( 3 ) were firmly connected to the actuation means (M), whereas in the present invention each door panel ( 3 ) can be always actuated, being released from the corresponding movement component ( 61 ); in order to do this, it is sufficient to apply a force on the door panel ( 3 ) that is capable of overcoming the attraction force between the magnet ( 92 ) and the metal bracket ( 93 ) that removably connect the door panel ( 3 ) to the corresponding movement component ( 61 ), and then manually rotate the door panel ( 3 ) that is freely pivoted with respect to the upper crosspiece ( 12 ) of the box frame ( 1 ).
[0110] Another circumstance in which the structure of the display ( 200 ) of the invention shows its advantages is when the door panels ( 3 ) close due to a malfunctioning of the detection means (R), while a user is picking a product that is contained in the interior of the display ( 200 ).
[0111] In such a situation the door panels ( 3 ), which are pushed by the actuation means (M) towards the closing position, interrupt the closing travel, being released from the movement component ( 61 ) as soon as the vertical lateral border ( 3 a ) of the door panel ( 3 ) intercepts the user's arm.
[0112] An additional advantage of the display ( 200 ) consists in the easy mounting and dismounting of the door panels ( 3 ), said door panels ( 3 ) being hinged to the display ( 200 ) only by means of the second pivoting pin ( 70 ) and the second section ( 71 b ) of the first pivoting pin ( 71 ).
[0113] Furthermore, an additional advantage is represented by the fact that the display ( 200 ) comprises only one electric motor ( 81 ) used to actuate all the panel doors ( 3 ). Having only one electric motor ( 81 ), the door panels ( 3 ) are moved in a synchronous manner, without having to be calibrated either electrically or electronically.
[0114] According to an additional embodiment of the invention, which is shown in FIG. 8 , the movement component ( 61 ) is a plate and comprises a horizontal portion ( 61 a ) that extends above the upper edge ( 3 b ) of the door panel.
[0115] The horizontal portion ( 61 a ) comprises a lower side ( 611 ) directed towards the upper edge ( 3 b ) of the door panel ( 3 ).
[0116] The fast coupling/uncoupling means ( 92 , 93 ) comprise magnetic retention means and, in particular, advantageously comprise a magnet ( 92 ) fixed on the lower side ( 611 ) of the horizontal portion ( 61 a ) of the movement component ( 61 ), and a metal bracket ( 93 ) fixed on the upper edge ( 3 b ) of the door panel ( 3 ).
[0117] Such an arrangement of the fast coupling/uncoupling means ( 92 , 93 ) provides for an additional advantage, which is represented by the fact that the door panels ( 3 ) can be released from the corresponding movement component ( 61 ) in both directions, both in opening and closing direction.
[0118] Otherwise said, if a door panel ( 3 ) is blocked in complete or partial opening position because of malfunctioning, the user could close the door panels ( 3 ) by pulling them towards him/her and releasing the door panel ( 3 ) from the corresponding movement component ( 61 ).
[0119] With reference to FIG. 3 , the display ( 200 ) advantageously comprises a switch (I) that can be operated manually by a user to actuate the door panels ( 3 ).
[0120] In particular, said switch (I) is configured in such a way to send an activation signal to the actuation means (M) that actuate the hinging means to rotate each door panel ( 3 ) around its axis of rotation (Y-Y).
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A display has at least one pair of revolving door panels hinged to a box frame by means of hinging means actuated by actuation means intended to permit the synchronous movement of the door panels of the pair of door panels.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention is directed to a method for adjusting the flow and the temperature of wash water when washing out contaminates, such as excess chemicals, from fabric webs in textile processing. In particular, an open-width washing machine is used in which a fabric web is conducted through a plurality of wash tubs connected in series and the warm wash water is conducted through these wash tubs in counter-current flow, whereby the flow and the temperature of the wash water are set.
2. Description of the Related Art
During washing of fabric webs in textile processing, the extent of the wash-out or of what is referred to as the washing action can be monitored with contaminate concentration sensors. For example, such a contaminate concentration sensor is a pH meter or a conductivity sensor that measures the extent of the conductivity of the fabric contaminated with excess chemicals. Such a sensor can be pressed against the fabric upon input into the machine and upon output from the machine. The water flow and the water temperature can thereby be set for a defined value of the desired washing action given a fabric of a defined quality. This, however, is only valid for a single fabric quality, and a different setting of the water flow and of the temperature must be applied given a different fabric quality in order to achieve the corresponding washing action.
In general, the water flow and water temperature is set at an excess of water and at a higher than needed temperature that are so broadly dimensioned that the desired washing action is achieved for all fabric qualities. Considerable energy is required for this washing process given the excess flow rate setting and high temperature setting to bring the rinse water, or wash water, and the fabric to be washed up to temperature, to maintain the required temperatures, i.e. to compensate energy losses that occur, and to drive the machines.
Practice has shown that the thermic yield of the washing process is frequently not optimum. The desired washing action, namely, can be achieved in various ways, whereby the following are valid at the extremes: (a) a great quantity of water and low temperature or (b) little water and a high temperature. In general, the known process is carried out with too much wash water and too high a temperature, this leading to high energy costs. Particularly given increasing (excessively high) temperature, the energy losses (and, consequently, the energy costs) rise exponentially, among other things because the evaporation of the water is far greater at high temperature.
SUMMARY OF THE INVENTION
The present invention eliminates the afore-mentioned problems and provides an improved method with which an optimally cost-beneficial adjustment of flow and temperature of the wash water is achieved in a fast way while obtaining the desired washing effect. This method is employable for all fabric qualities. When the method of the invention is applied using an open width washing machine, the advantages are achieved in such fashion that the wash water flow and the washing action are measured with a measurement at a water temperature and a corresponding, first replacement factor is calculated therefrom; in that the wash water flow and the washing action are measured again with a further measurement at a further temperature and another, corresponding, second replacement factor is calculated therefrom, the linear relationship M=f(T) being calculated from said first replacement factor, said second replacement factor and corresponding temperatures; and that the corresponding, required replacement factors and - via the said linear relationship - the required temperatures are calculated for continuously incrementing values of wash water flow and desired washing action in the flow range, whereby the costs of the consumption of wash water flow and steam are respectively calculated and the corresponding wash water flow and the corresponding steam delivery are set on the basis of the minimum value of these costs deriving therefrom.
In such an embodiment of the invention, it is possible to adapt an open-width washing machine in such fashion than economical system is obtained while obtaining the desired washing action. As a result thereof, the average energy consumption can thereby be reduced by 40 to 50 percent in comparison to the known method.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of an open-width machine having three wash tubs divided into washing compartments;
FIG. 2 is a schematic diagram of a washing apparatus showing the principle of the measuring and control elements that are employed in the method of the invention;
FIG. 3 is a functional block diagram of a control unit employed to practice the invention;
FIG. 4 is a schematic diagram of a washing apparatus for explaining the calculation of the replacement factor to be applied to a washing compartment;
FIG. 5 is a graph showing an example of the relationship between the phase relationship and the temperature at a defined washing action;
FIG. 6 is a graph showing an example of the relationship between the operating costs and a combination of wash water flow and temperature given a defined washing action;
FIG. 7 is a graph showing an example of the relationship between replacement factor and temperature;
FIG. 8 is a flow chart for defining the relationship between the replacement factor and the temperature; and
FIG. 9 is a flow chart of the cost-minimum adjustment of wash water flow and temperature.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 schematically shows an open-width washing machine in which excess chemicals such as alkali and reaction products derived from steeping and bleaching treatments are rinsed out of a fabric web 3. For example, such a machine has three wash tubs 5, whereby every wash tub 5 is divided into three series-connected washing compartments 1 in order to increase the washing action. Wash water 2 is conducted through the machine in a counter-current flow method, whereby the fresh rinse water 2 flows into the machine at the right-hand side and subsequently flows through all compartments. The textile or fabric web 3 to be washed enters into the machine at the left-hand side and is conducted through all compartments on rollers 12. The fabric running can thereby be both vertical as well as horizontal. The fabric 3 is pressed by a pressing or wringing unit 4 after every wash tub 5 and the water that is wrung out returns into the flowing wash water 2 through a conduit 14. The wash water 2 is brought to temperature and held at temperature per wash tub, for example, by blowing hot steam in, shown for example in FIG. 2. At the same time, a contaminate concentration sensor, such as one of conductivity sensors G1, G2 and G3, that is pressed against the fabric has been attached at the admission and, potentially, at one of the wash tubs, and at the discharge, also as shown in FIG. 2. PG,6
In practice, wash water consumption and temperature (i.e., steam delivery) are generally heretofore selected such that a good rinsing or washing effect is obtained under all conditions. This almost always means too much wash water and excessively high temperatures, which in turn leads to high energy costs.
The invention now provides a method for the optimum adaptation of wash water flow and temperature so that an energy savings is realized while obtaining the desired washing action. The method is practiced by the apparatus as shown in FIG. 2. Flowmeters W and S are arranged in both main delivery lines for measuring the wash water consumption and steam consumption, respectively, and temperature sensor T1 through T6 such as, for example, a Pt-100 element have been installed in the individual wash tubs for the temperature measurements. A velocity meter V for the speed of the fabric web 3 has likewise been provided. The valves K1 through K6 in the steam delivery lines are preferably flow-controlled, pneumatic valves, as is the wash water valve K7. The conductivity sensors G1 through G3 have been attached at the admission of the fabric web 3, in of the wash tubs 5 and at the discharge of the fabric web 5 in order to measure the contamination of the fabric.
A control unit 8 as provided in FIG. 3 can be a microcomputer. The measured data of the temperature sensors T, of the conductivity sensors G and of the meters W, S, V are collected by a data logger 6 that forwards them via an interface 7 to the control unit 8 once every ten seconds. The control signals in binary code deriving from the control unit 8 are converted via an interface 9 into control signals of 4 through 20 mA for the valves K1-K7 referenced 10 in general. A proportional control is thereby applied for the water flow and a PID control is applied for the temperature.
The control ensues on the basis of measuring the concentration of the contamination in the fabric, for example on the basis of the conductivity that proportionally corresponds to this concentration of the contaminate. The value of the desired conductivity after n compartments or wash tubs 5, together with the conductivity measured at the admission, yields the desired washing action φ this is the conductivity C n of the fabric at the discharge divided by the conductivity C o at the admission: φ=C n/ C o . The optimally cost-beneficial combination of water flow and temperature is calculated for this desired washing action, whereupon this is set via the valves K1-K7 and is reset in case of deviations.
It is assumed in general that every washing compartment 5 has the same washing action given an identical water flow and given the same temperature. Since this is not always the case in practice, for example, as a consequence of the dimensions of the compartments and of the pressing or wringing of the wash water from the fabric between specific compartments, one works with the average washing action per compartment.
FIG. 4 shows a schematic illustration of an open-width washing machine comprising a plurality of i compartments or tubs 5 into which the fabric 3 is introduced at the left and is discharged at the right and the contamination of this fabric decreases from left to right. The contamination in the wash water flow 2 thereby increases from right to left. C o ...C i-3 , C i-2 , C i-1 , Ci is the contaminate concentration of the fabric between each compartment 5 as well as before the first and after the last compartment. K o ...K i-3 , K i-2 , K i-1 , Ki is the concentration of the contamination in the wash water 2. A replacement factor M for a washing compartment is thereby defined as the fraction of the liquid or contaminant entering together with the fabric that is replaced by wash water. In other words, the replacement factor is the change in the contaminant concentration of the fabric as it passes through the respective compartment over the amount of the contaminant transferred from the fabric to the wash water in that compartment.
M=(C.sub.i-1 -C.sub.i)/(C.sub.i-1 -K.sub.i-1) (1)
Given complete replacement, M=1 applies, and M=0 applies given no replacement. The replacement factor M proves to be linearly dependent on temperature in the working range:
M=RC·T+B(T in °C.) (2),
wherein RC and B are constants that are defined by the type of wash compartment and by the fabric quality. M is likewise independent of the size of the water flow. According to a simple wash model, a function for the relationship between that fraction φ=C n /C o that is not washed out can be derived from the replacement factor M and from the liquid flow rate. This relationship can be written in the following way:
C.sub.n /CO=(1-F)/(1-F(F/P).sup.n) (3),
wherein F is the phase relationship or the volume of the wash water supplied per second divided by the volume of the wash water entrained with the fabric per second, and wherein P=F-MF+M. A fixed, average value is thereby assumed for the volume of the water entrained with the fabric per second.
On the basis of the afore-mentioned equations (2) and (3), their relationship between the washing action φ=C n /C O , the wash water temperature T and the phase relationship F can be calculated, as recited by way of example for a defined washing action as shown in FIG. 5. It proceeds from FIG. 5 that a defined, desired washing action can be achieved with a great plurality of adjustments of water flow and temperatures. In order to calculate the optimally cost-beneficial combination, the costs of steam and water at these settings must be known.
The quantity of steam required for heating the wash water and the fabric covers the theoretically required quantity of steam in order to bring the wash water and the fabric to temperature (linearly dependent on the temperature) and the required quantity of steam for compensating the thermal losses.
When the overall costs for water and steam are set off compared to the individual combinations of water flow and temperature that produce a defined, desired washing action, the relationship as shown in FIG. 6 derives. It proceeds from FIG. 6 that an optimally cost-beneficial combination of water flow and temperature can be found for every desired washing action.
On the basis of the earlier data, the following control model or method is provided which is practiced by the control unit:
(1) inputing the measured values into the control unit;
(2) calculating the means value of the measured values;
(3) calculating the replacement factor M from the measured washing action φ=C n /C O and from the water flow rate;
(4) calculating the relationship between the replacement factor M and temperature T;
(5) identifying the optimally cost-beneficial combination of water flow and temperature given a desired washing action;
(6) setting the points of adjustment for the valves.
When the equation (3) already mentioned above is rewritten, the following equation is obtained for the average replacement factor M: ##EQU1## wherein n=the plurality of compartments (for example, 12). From the equation (4) already recited above, a value of M that belongs to a desired washing action and to a selected value of water flow follows for a washing machine having a plurality of n compartments. In order to be able to calculate at what water temperature the desired value M (for a desired washing action) is achieved given a specific open-width washing machine, the relationship between these two quantities must be known. Given the assumption that this relationship is linear, the directional coefficient (RC) and the axis crossing (B) of the straight line M=f(T) must first be calculated.
With reference to FIG. 7, this relationship is calculated in the following way:
in a first measurement pass, the corresponding M-value is calculated at a defined temperature from the average measured values of the conductivity at the admission and at the discharge and from the water flow, this yielding a first estimate of the directional coefficient RC of the function M=f(T).
In a second measurement pass, a second, corresponding M-value is calculated at a following temperature from the measured values of the conductivity and from the flow. A new directional coefficient RC is calculated from this second corresponding M-value and the next most recently calculated M-value. The last two M-values are always used in this way in order to define the straight line M=f(T).
The following situations can derive in these calculations, as is likewise recited in the flow chart of FIG. 8:
(1) a value of zero is assumed in a first measurement for the axis crossing.
(2) When the measured temperatures T 1 and T 2 are different in a following measurement, the straight line is defined in the following way:
RC=(M.sub.2 -M.sub.1)/(T.sub.2 -T.sub.1) and B=M.sub.2 -RC·T.sub.2 (5),(6)
(3) When the measured temperatures T 1 and T 2 are identical in a following measurement or when a negative RC or B arises due to any cause whatsoever, the straight line is defined in the following way:
RC=(M.sub.2 -B.sub.o)/T.sub.2. (7)
B o therein is the most recently measured value of B and a fixed, practical value is assumed for B o when this is too high.
After the afore-mentioned relationship between M and T has been calculated, the corresponding, desired replacement factor M and the corresponding temperature T can be calculated proceeding from an initial value and, following thereupon, from incrementing values of the water flow in the flow range. The corresponding costs are calculated for these subsequent combinations of water flow and temperature and that combination having the minimum costs is selected therefrom. This combination of water flow and temperature is then set, all as recited in the flow chart of FIG. 9.
The attached table 1 recites the results obtained for a series of fabric webs with the earlier method and with the new method. It is clear that a considerable energy savings is achieved while retaining the required washing action.
Although other modifications and changes may be suggested by those skilled in the art, it is the intention of the inventor to embody within the patent warranted hereon all changes and modifications as reasonably and properly come within the scope of his contribution to the art.
TABLE I__________________________________________________________________________Average Results of Five Tests carried out in practice Tests With the Control Normal Self- System Control No. 1 No. 2 No. 3 No. 4 No. 5__________________________________________________________________________Type of Fabric Cotton Cotton Cotton Cotton Cotton Cotton CottonFabric Weight in g/m.sup.2 225 250 260 263 340 195 135Weave Flat Twill Twill Satin Satin Flat FlatTemp Tub No. 1 95 95 60 59 85 45 45erature Tub No. 2 94 95 60 59 85 45 45in °C. Tub No. 3 80 80 60 59 85 45 45 Tub No. 4 70 70 60 59 70 45 45 Tub No. 5 60 60 60 59 70 45 45 Tub No. 6 50 50 50 50 50 45 45Conductivity Admission 420 412 437 2,018 996 346 614of the After TubFabric No. 3 58 60 75 77 110 55 41(in μS) After Tub No. 6 20 21 22 20 24 18 19Wash Water Flow in 6.0 6.0 5.8 5.3 8.0 4.0 4.0m.sup.3 /h)Steam consumption 1,360 1,360 864 740 1,650 235 220(in kg/h)Costs (NFl/h) 88 88 60 52 107 21 20Control Time 0:57 1:00 0:48 1:53 1:19 1:46 1:48(h:min)__________________________________________________________________________
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A method for adjusting the flow and the temperature of wash water when washing out contaminations from fabric webs in textile processing methods upon employing of an open-width washing machine, whereby replacement factors are calculated at different temperatures and the costs of the wash water flow and steam consumption are consequently calculated and the corresponding wash water flow and the corresponding steam delivery are set for minimizing these costs.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of PCT/EP2008/003894, filed May 15, 2008, which claims the priority of German patent application DE 10 2007 024 256.7, filed May 16, 2007, which are each incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a vascular stent, in particular a coronary stent.
BRIEF SUMMARY OF THE INVENTION
[0003] Stents are used medically as implants to keep open and/or after an occlusion (stenosis) to re-open hollow structures of organs in the body. As a rule, in this case a small tubular stent in compressed form is introduced into the relevant organ and then expanded in order to support the walls of the organ.
[0004] Stents are of particular significance for opening blood vessels, and here in particular in the region of coronary vessels (coronary stents). Stenosis or occlusion of coronary vessels as a result of the depositing of thrombi (blood clots), blood fats or calcium on the vessel walls is a frequent cause of areas of the myocardium being under-supplied with blood and hence of cardiac infarction. The stents used to prevent or eliminate such stenoses frequently comprise a small tubular lattice frame that is introduced into the relevant vessel and radially expanded by means of a balloon catheter in order to widen the vessel to an adequate size.
[0005] Such therapies involving vascular stents however regularly give rise to the problem of so-called restenosis. By this is meant a renewed narrowing of the vessel as a result of on-stent deposits and/or overgrowth of the stent with tissue, this being induced by an activation of blood platelets and clotting factors on the “foreign material” of the stent (as a rule, metal or plastics material). Restenosis often necessitates renewed treatment of the affected vessel.
[0006] For some time now drug-coated stents (drug-eluting stents, DES) have been used to avoid or reduce this problem. These stents have a coating, from which specific active substances for inhibiting the formation of tissue (for example anti-proliferatives, cytostatic drugs or immuno-suppressants) are released. Through the use of such stents the risk of restenosis of the relevant vessel is to be markedly reduced (see M. C. Morice et al., New England Journal of Medicine 2002 (346) 1773-1780).
[0007] Drug-coated stents are disclosed i.a. in the published patent application US 2005/0019404 A1.
[0008] In recent studies it was however discovered that for patients, in which after stenosis of a coronary vessel a drug-coated stent was implanted, the mortality rate is higher than for patients who were treated with an uncoated metal stent. The quantitative result of this study was that the probability of death by cardiac infarction in the period of between 6 months and 3 years after the stent implantation was 32% higher in the first-mentioned patient group than in the last-mentioned patient group (see B. Lagerqvist et al., New England Journal of Medicine 2007 (356) 1009-1019).
[0009] The object of the present invention is to provide a stent, with which the risk of restenosis is reduced without having to use anti-proliferative active substances.
[0010] This object is achieved according to the invention by a vascular stent of the type described in the introduction, comprising a carrier of a dimensionally stable material, as well as one or more layers, which are disposed at least in sections on the carrier, of a material based on crosslinked gelatin that is resorbable under physiological conditions, wherein the adhesion between the carrier and the layer and/or between individual layers can be neutralised.
[0011] This removal of the adhesion promotes a separation of one or more layers from the stent according to the invention under physiological conditions. The physiological conditions, to which the vascular stent according to the invention is exposed during its use in the body of a human or animal, i.e. in particular the conditions prevailing in the blood, may be defined in this case by so-called physiological standard conditions and reconstructed in vitro. By physiological standard conditions in the context of the present invention is meant the incubation in PBS buffer (pH 7.2) at 37° C.
[0012] Preferably, one or more layers of the resorbable material are detachable individually. By the detachment of a layer in the sense of the present invention is meant an, at least in sections, two-dimensional separation of the resorbable material that forms the layer from the layer underneath or from the carrier. In other words, what occurs is a detachment of sections or fragments of the layer that still possess a certain structural integrity. This separation process is to be regarded as in contrast to a continuous degradation or resorption of the layer on a molecular level, whereby the layer is substantially fully resorbed before a detachment in the sense described above occurs.
[0013] The advantageous effect of the stent according to the invention is based on the fact that, by virtue of the neutralisation of the adhesion and the separation of one or more layers of the resorbable material from the vascular stent, cells, tissue or thrombi that have formed on the surface of the stent are also separated from the stent and removed by the blood stream from the relevant region of the vessel. Thus, this process leads to a cleaning of the stent and a renewal of its surface, thereby preventing or at least delaying restenosis without any need to use anti-proliferatives or similar active substances.
[0014] For the present invention the initially existing adhesion between the layer and the carrier and/or between the layers is important in order that by means of the controllable neutralisation of the adhesion the separation of two-dimensional layer parts is possible in a purposefully timed and predeterminable manner and the stent exhibits defined properties up to the start of the separation.
[0015] The possibility of neutralising the adhesion between individual layers that is provided according to the invention may be achieved by various measures. Firstly, adhesive layers of a material that is soluble under physiological conditions may be provided between individual layers of the resorbable material. For such adhesive layers various materials are conceivable, for example low-molecular, soluble collagen hydrolysate.
[0016] Preferred carriers have a microscopically smooth, closed surface. When the layers are applied to the carrier, this prevents material from depositing in pores, thereby resulting in an adhesion based on positive-locking effects. This applies in particular also in the case of the use of carriers in the form of small tubular lattice frames, which are also particularly suitable for the present invention. In the case of carriers having a lattice frame structure, the special advantage is achieved that during the two-dimensional separation of a layer no physiologically over-large and hence medically dangerous layer pieces are released into the blood circulation.
[0017] In the case of carriers having a lattice structure the preferred aim is a coating of the webs of the carrier, which in cross section are preferably completely surrounded by the layer and/or layers. Even after coating of the webs of the carrier, the spaces between the webs remain preferably open.
[0018] An expansion of the stent is then possible without threatening the integrity of the layer(s) on the carrier, i.e. the layer(s) on the webs of the carrier.
[0019] Furthermore, separating layers may also be provided between individual layers of the resorbable material, this being discussed in more detail further below.
[0020] The neutralisation of the adhesion between individual layers of the resorbable material (and/or between the carrier and the adjacent layer) may in particular also be based on an at least partial degradation of the material under physiological conditions, wherein by degradation is meant primarily those processes that ultimately lead also to resorption of the material. The degradation properties of the resorbable material may in this case be purposefully influenced by various measures, for example by the use of gelatins of differing molecular weights and/or by the admixture of further biopolymers to the gelatin-based material.
[0021] According to a preferred embodiment of the invention, the adhesion may be neutralised in dependence upon the degree of crosslinking of the gelatin. A higher degree of crosslinking of the gelatine leads to a slower degradation (and resorption) of the gelatin-based material, so that by means of this parameter the separation behaviour of individual layers may be adjusted in a simple manner.
[0022] In a particularly preferred manner the gelatin is crosslinked in such a way that the degree of crosslinking decreases within one or more layers of the resorbable material in the direction of the carrier. The effect achieved by a lower degree of crosslinking of the gelatin at the side of a layer facing the carrier is that in this region a faster degradation of the material occurs and hence the adhesion to the carrier (and/or to the layer underneath) is neutralised, while at the outside of the layer as a result of the higher degree of crosslinking of the gelatin a certain structural integrity is maintained and the previously described, at least in sections, two-dimensional separation of the layer is achieved.
[0023] The dimensionally stable material, from which the carrier is formed, is preferably a material that is inert under physiological conditions, in particular metal and/or plastics material. As carriers it is possible to use in particular expandable lattice frames or similar structures in the form of a small tube or hose.
[0024] The vascular stent according to the invention is used preferably in the cardiovascular area, and here in particular for the treatment of coronary vessels (coronary stent) because, here, vascular stenoses may lead to a cardiac infarction. The stent may however equally be used to treat stenoses in other areas of the body.
[0025] The effect according to the invention of at least reducing the risk of restenosis may already be achieved by arranging the layer(s) in sections on the carrier. It is however preferred if the at least one layer covers ca. 75% or more, in particular ca. 90% or more of the surface of the carrier. In a particularly preferred manner the at least one layer covers substantially the entire surface of the carrier.
[0026] The use according to the invention of gelatin as a base material for the layer(s) of resorbable material offers the advantage that gelatin is a substantially fully resorbable product that is tolerated extremely well by the body and may be manufactured in a reproducible purity and quality.
[0027] Within the framework of the present invention gelatin moreover has a particularly advantageous effect insofar as it promotes angiogenesis, i.e. the regeneration of blood vessels. Studies relating to this have shown that by introducing gelatin-containing shaped bodies into the body of a human or animal a local angiogenesis-promoting effect occurs. This applies not only to shaped bodies which are porous, where a growing of capillary vessels into the porous structure was observed (see German patent application 10 2005 054 937), but in particular also to shaped bodies which are non-porous, such as for example films, where the angiogenesis-promoting effect is observed in the area surrounding the shaped body.
[0028] It was discovered that the cause of the initially mentioned higher mortality with drug-coated stents lies primarily in an undesirable side effect of the anti-proliferative active substances used in the coated stents, namely a prevention of angiogenesis in the area surrounding the relevant vessel. In the event of stenosis, a natural reaction of the body is to bridge the occlusion by regenerating blood vessels. As this process is inhibited by anti-proliferatives or the like, in the event that restenosis nevertheless occurs no collateral blood vessels are available and the result is a cardiac infarction (P. Meier et al., Journal of American Cardiology 2007 (49) 15 to 20).
[0029] The possibility of dispensing with anti-proliferative active substances in the stent according to the invention means that not only is an angiogenesis-inhibiting effect avoided but, on the contrary, angiogenesis is stimulated by the gelatin-based material.
[0030] The vascular stent according to the invention therefore, on the one hand, reduces or delays the risk of restenosis as a result of the self-cleaning effect of the stent surface and, on the other hand, simultaneously promotes the generation of collateral blood vessels owing to the angiogenesis-promoting effect of the gelatin in the area surrounding the relevant vessel. Should restenosis nevertheless occur, in particular after all of the layers of the stent have separated, collateral blood vessels are available as a natural bypass system.
[0031] Dispensing with anti-proliferative agents moreover offers further advantages. For example, these active substances prevent not only the depositing of tissue, which may lead to restenosis, but also endothelialization of the stent. Endothelialization produces around the stent a layer of connective tissue that is compatible with the components of the blood, thereby preventing the activation of blood platelets and clotting factors on the stent material, i.e. this process counteracts a thrombosis in the region of the stent.
[0032] The resorbable material according to the invention is preferably formed predominantly by crosslinked gelatin. This means that the gelatine represents the largest fraction compared to any further components of the material that are used.
[0033] Particularly suitable types of gelatin are pork-rind gelatin, which is preferably high-molecular and has a Bloom value of ca. 160 to 320 g.
[0034] In order to guarantee an optimum biocompatibility of the stent according to the invention, as a starting material preferably a gelatin having a particularly low endotoxin content is used. Endotoxins are metabolic products or fragments of microorganisms that occur in the raw animal material. The endotoxin content of gelatin is indicated in international units per gram (I.U./g) and determined in accordance with the LAL test, the performance of which is described in the fourth edition of the European Pharmacopoeia (Ph. Eur. 4).
[0035] In order to keep the endotoxin content as low as possible, it is advantageous to destroy the microorganisms as early as possible in the course of gelatin production. Furthermore, appropriate hygiene standards should be observed during the production process.
[0036] The endotoxin content of gelatin may therefore be drastically reduced by specific measures during the production process. These measures primarily include the use of fresh raw materials (for example pork rind) avoiding periods of storage, careful cleaning of the entire production plant immediately before the start of gelatin production and optionally the replacement of ion exchangers and filter systems in the production plant.
[0037] The gelatin used within the framework of the present invention preferably has an endotoxin content of ca. 1,200 I.U./g or less, even more preferably of ca. 200 I.U./g or less. Optimally the endotoxin content is ca. 50 I.U./g or less, determined in each case in accordance with the LAL test. Compared to this, many commercially available gelatins have endotoxin contents of more than 20,000 I.U./g.
[0038] By means of the crosslinking according to the invention of the as such soluble gelatin, the gelatin is converted to an insoluble material that is however resorbable under physiological conditions. In this case, the rate of resorption and/or degradation of the material is dependent upon the degree of crosslinking of the gelatin and may be adjusted over a relatively wide range, as has already been mentioned above. In particular, the point in time of the detachment of individual layers may be preselected by means of the respective degree of crosslinking of the gelatin.
[0039] Shaped bodies based on crosslinked gelatin, the resorption properties and the manufacture thereof are described in the published patent application DE 10 2004 024 635 A1.
[0040] The crosslinking of the gelatin may be effected both by chemical and by enzymatic crosslinking agents. Of the chemical crosslinking agents a crosslinking using formaldehyde is preferred, which simultaneously effects sterilization.
[0041] A preferred enzymatic crosslinking agent is the enzyme transglutaminase.
[0042] A suitable procedure for the manufacture of shaped bodies based on crosslinked gelatin is a two-stage crosslinking process, whereby in a first stage the gelatin is partially crosslinked in solution. From the partially crosslinked gelatin solution a shaped body is then manufactured and subjected to a second crosslinking step.
[0043] The second crosslinking step may be carried out in particular by the action of a crosslinking agent in the gas phase, preferably formaldehyde.
[0044] In accordance with this method the vascular stent according to the invention may be manufactured by applying a partially crosslinked solution of the gelatin-based material onto the surface of the carrier, for example by dipping the carrier into the solution. After drying of the solution, a carrier having a layer of the resorbable material is obtained, which is then subjected to the second crosslinking step, for example with formaldehyde in the gas phase.
[0045] This second crosslinking step is a simple way of obtaining the preferred gradient in the degree of crosslinking because the crosslinking agent is able to penetrate into the layer only from the outside of the layer, this leading to a higher degree of crosslinking at the outside and a lower degree of crosslinking at the inner side facing the carrier.
[0046] Within the framework of the invention it is equally conceivable to provide no crosslinking of the gelatin in the solution but only a single crosslinking step after applying the layer onto the carrier.
[0047] The resorbable material preferably contains one or more softening agents. This increases the flexibility of the material, which may be advantageous particularly with regard to the expansion of the stent after implantation. An adequate flexibility makes it possible extensively to prevent the at least one layer from becoming damaged or from mechanically separating from the carrier during expansion of the stent.
[0048] Preferred softening agents are for example glycerine, oligoglycerines, oligoglycols, sorbitol and mannitol. The softening agent content in the resorbable material is preferably ca. 12 to ca. 40 wt. %, more preferably ca. 16 to ca. 25 wt. %.
[0049] According to a preferred embodiment of the invention, a plurality of layers of the resorbable material are disposed on the carrier. By providing a plurality of layers, which detach preferably in each case individually, the surface of the stent according to the invention may be repeatedly freed of deposits and so the period, during which the risk of restenosis is reduced, can be markedly prolonged. The vascular stent preferably comprises two to five layers of the resorbable material.
[0050] Stents according to the invention having a plurality of layers are relatively easy to manufacture by carrying out the previously outlined method steps (applying the optionally partially crosslinked gelatin solution, drying and second crosslinking) a number of times in succession.
[0051] The degree of crosslinking of the gelatin within each layer preferably decreases in the direction of the carrier. This promotes the neutralisation of the adhesion for the separation of each individual layer.
[0052] The individual layers of the resorbable material are advantageously detachable successively from the outside in. Such a successive detachment is already promoted by the fact that the layers situated further in are protected to a certain extent from degradation in each case by the layers situated above. This applies even if all of the layers have the same average degree of crosslinking of the gelatin.
[0053] It is however preferred if the average degree of crosslinking of the individual layers increases in the direction of the layer adjacent to the carrier. By means of a high degree of crosslinking of the inner layers, the degradation and detachment of these layers may be additionally delayed. Furthermore, the separation behaviour of the individual layers may be purposefully adapted to the respective requirements, i.e. in particular to the anticipated intensity of deposits and/or tissue formation on the stent. Ideally, the period up to detachment of the innermost layer is long enough to allow collateral blood vessels to be generated, promoted by the angiogenesis-promoting effect of the gelatin-based material, before this detachment occurs.
[0054] The average degrees of crosslinking of the individual layers may be selected for example in such a way that the outermost layer detaches after ca. 1 to 2 weeks and the innermost layer adjacent to the carrier detaches after ca. 3 to 6 months. The specified periods refer to the time, at which the stent according to the invention is exposed to physiological conditions, i.e. is in particular inserted into a blood vessel.
[0055] Different degrees of crosslinking of the individual layers may be realized in the previously described manufacturing method by different concentrations of crosslinking agent in the gelatin solution and/or by different concentrations or reaction times of the crosslinking agent in the second crosslinking step.
[0056] The thickness of the individual layers of the resorbable material is preferably in the region of ca. 5 to ca. 50 μm.
[0057] According to a further embodiment of the invention, one or more separating layers are disposed between a plurality of layers of the resorbable material and/or at the outside of the layer(s). By means of such separating layers various advantageous effects may be achieved.
[0058] First of all, the adhesion between a plurality of layers may be reduced by means of the separating layers. With progressive degradation of the gelatin-based material in the respective outermost layer, the neutralisation of the adhesion and the separation of this layer is accelerated by means of the separating layer, wherein the separating layer itself remains on the outside of the layer situated underneath.
[0059] A resorbable material is preferably used for the separating layers. This material preferably has a longer resorption time than the gelatin-based material in the at least one layer, so that the separating layer is still present on the outside of a layer at the time of the detachment of this layer.
[0060] The separating layers may be formed for example by a releasing wax.
[0061] A further effect that may be achieved by means of a separating layer disposed on the respective outermost layer is that the deposit of cells or tissue on the surface of the stent is reduced by virtue of the separating layer having an adhesion-inhibiting effect with regard to these deposits. This additionally counteracts the risk of restenosis. If the extent of the deposits is reduced, a later time of detachment of the layer(s) of the resorbable material may also be selected.
[0062] The at least one separating layer preferably contains modified gelatin. It has been found that by means of a chemical modification of gelatin an adhesion-inhibiting effect with regard to cells may be achieved.
[0063] According to a further embodiment of the invention, it is provided that the modified gelatin is contained in one or more layers of the gelatin-based material. In this way, an effect comparable to that in the case of separating layers of modified gelatin may be achieved.
[0064] While separating layers may be formed to a large extent or substantially entirely by modified gelatin, the possible content of modified gelatin in the layers is limited insofar as adverse effects on the crosslinkability of the gelatin and on the degradation behaviour should be avoided.
[0065] The modified gelatin is preferably a gelatin modified with fatty acid groups. One example of this is the modification of gelatin with dodecenylsuccinate.
[0066] The modification is effected here in particular at the free amino groups of the lysine groups of the gelatin. Preferably ca. 10 to ca. 80% of the lysine groups of the modified gelatin are modified with fatty acid groups.
[0067] A further possible way of achieving an adhesion-inhibiting effect is an anionic modification of the gelatin, for example the succination of side chains.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0068] These and further advantages of the invention are described in detail by way of the following examples and with reference to the drawings. The drawings specifically show:
[0069] FIG. 1 : representation of a stent according to the invention in a compressed state prior to implantation;
[0070] FIG. 2 : representation of a stent according to the invention in an expanded state after implantation;
[0071] FIG. 3 : representation of a detail of the structure of a stent according to the invention;
[0072] FIG. 4 : schematic cross-sectional representation of the layers of a stent according to the invention;
[0073] FIGS. 5 and 6 : graphs relating to the adhesion-inhibiting effect of modified gelatin;
[0074] FIG. 7 : photographic representation of the generation of blood vessels in the subcutaneous tissue of a mouse;
[0075] FIGS. 8 a to c : photographic representations of the increased generation of blood vessels in the presence of various angiogenesis-promoting substrates based on crosslinked gelatin; and
[0076] FIG. 9 : photographic representation of the time-dependent separation behaviour of two layers of a gelatin-based material.
DETAILED DESCRIPTION OF THE INVENTION
[0077] FIGS. 1 and 2 show an embodiment of a vascular stent according to the invention, which is used in particular as a coronary stent. The stent comprises a carrier in the form of a small tubular lattice frame made of metal or plastics material, on the surface of which a plurality of layers of a resorbable material based on crosslinked gelatin are disposed.
[0078] FIG. 1 shows the stent in a compressed state. The stent in this state has only a relatively small cross section and may therefore be introduced into a vascular region affected by stenosis.
[0079] After being implanted, the stent is widened for example by means of a balloon catheter, i.e. is expanded radially so that the affected vessel is wide open and supported by the stent. This expanded state of the stent is shown in FIG. 2 . Both the lattice frame of the carrier and the layers of resorbable material are flexible enough to allow this expansion process to occur.
[0080] FIG. 3 shows an enlarged detail of the frame structure of the stent according to the invention. The lattice frame of the carrier is formed by a plurality of interconnected webs, wherein the layers are disposed on the surface of these webs. Preferably, in the present case as large a proportion as possible of the total surface of the carrier is covered.
[0081] The geometry of the lattice structure and/or the arrangement of the webs that is shown in FIG. 3 is in the present case merely by way of example. The lattice structure should however be so designed that by bending or deforming the webs an expansion of the stent is possible.
[0082] A schematic representation of the cross section through a web 10 of the carrier, for example along the line A-A, is shown in FIG. 4 . The web, which for example has a diameter in the region of 100 to 200 μm, is surrounded by three layers, namely an inner layer 21 adjacent to the web 10 , a middle layer 22 and an outer layer 23 . As an alternative to this embodiment, one, two or more than three layers may be provided.
[0083] All of the layers are formed by a material based on cross-linked gelatin that is resorbable under physiological conditions. To increase the flexibility of the layers, the material may additionally comprise a softening agent, for example glycerine.
[0084] The degree of crosslinking of the gelatin preferably decreases within each of the three layers 21 , 22 and 23 in the direction of the web 10 of the carrier. This means that for example the outer layer 23 has a lower degree of crosslinking at its inner side, i.e. the side facing the middle layer 22 , than at its outer side 20 .
[0085] This gradual degree of crosslinking leads under physiological conditions to a faster degradation of the gelatin-based material at the inside of the layer 23 and hence, after a preselected time, to a neutralisation of the adhesion to the layer 22 and to an, at least in sections, two-dimensional separation of the layer 23 from the layer 22 . At the same time, deposits of cells or tissue that have formed on the outer side 20 of the layer 23 , i.e. on the surface of the stent, are removed from the associated vascular region by the blood stream. After this separation, the layer 22 forms the outer layer, so that the process just described may be repeated with this layer.
[0086] The average degree of crosslinking of the gelatin in the individual layers 21 , 22 and 23 preferably increases in the direction of the web 10 , i.e. the layer 23 has the lowest and the layer 21 the highest average degree of crosslinking.
[0087] For example, the degrees of crosslinking in the individual layers are selected such that the layer 23 detaches ca. one to two weeks, the layer 22 ca. four to eight weeks and the layer 21 ca. three to six months after introduction of the vascular stent into a blood vessel.
[0088] The individual layers 21 , 22 and 23 preferably have a thickness in the region of ca. 5 to ca. 50 μm.
[0089] Separating layers may be disposed between the individual layers 21 , 22 and 23 and/or on the outer side 20 of the layer 23 . Such separating layers may, on the one hand, accelerate the neutralisation of the adhesion between the individual layers and/or counteract the adhesion of cells and tissue.
[0090] The separating layers and/or the layers 21 , 22 and 23 may in particular contain modified gelatin. In this way, the cell adhesion with regard to non-modified gelatin may be reduced, as is demonstrated in the following Example 1.
Example 1
Inhibition of Cell Adhesion by Modified Gelatin
[0091] The amino groups of the lysine groups in the gelatin may be converted to a succinated form by means of succinic acid anhydride, with the result that the pK s value of the gelatin material of 8 to 9, as is found for the unmodified gelatin, is lowered to ca. 4.
[0092] A further possible way of modifying the gelatin is to convert the amino groups of the lysine groups to dodecenyl-succinyl groups. The pK s value in this case is reduced to ca. 5 and at the same time a slight hydrophobing of the gelatin by the fatty acid group occurs.
[0093] In both cases, the cell adhesion with regard to a gelatin treated in this way decreases markedly, which is demonstrated in the tests described below using the example of porcine chondrocytes.
[0094] The degree of conversion of the lysine groups of the modified gelatin is preferably 30% or more. In the case of the dodecenyl-succinated gelatin degrees of conversion of 40 to 50% are often eminently sufficient, whereas in the case of the succinated gelatin an 80% to almost total conversion of the lysine groups produces the best results.
[0095] FIGS. 5 and 6 show cell adhesion results for test areas, applied for test purposes onto glass surfaces, of gelatin materials that were manufactured from pork-rind gelatin (MW 119 kDa) and a gelatin ca. 95% succinated at the lysine groups ( FIG. 5 ) and ca. 45% dodecenyl-succinated gelatin ( FIG. 6 ), respectively, of an identical type. In each case mixtures of unmodified gelatin with modified gelatin in the ratios 100:0, 80:20, 50:50 and 0:100 were tested.
[0096] In the tests in each case 20,000 porcine chondrocytes were incubated on a test area for 4 hours at 37° C. The excess was removed, the surface washed and the cells remaining on the surface fixed for subsequent analysis under a light-microscope. Comparable results were obtained with human chondrocytes.
[0097] The percentages indicated in the graphs represent the proportion of cells found on the film test areas compared to the number used for incubation, after the previously described procedure was carried out.
[0098] For both types of modified gelatin, population effects close to zero were obtained in the case of exclusive use of modified gelatin.
[0099] This marked inhibition of the cell adhesion by chemically modified gelatin may be utilized within the framework of the present invention to reduce the deposit of cells and tissue on the respective outer layer of the stent.
[0100] The separating layers preferably disposed between the individual layers may in this case contain a very high proportion of modified gelatin of up to 100%. As these separating layers, after detachment of the layer situated above, form in each case the surface of the stent, a very strong adhesion-inhibiting effect of the stent according to the invention may therefore be achieved.
Example 2
Promotion of Angiogenesis
[0101] The following example is intended to demonstrate the local angiogenesis-promoting effect of gelatin-based materials.
[0000] Manufacture of Films from a Gelatin-Based Material
[0102] Gelatin films having three different degrees of cross-linking (films A, B and C) were manufactured by means of a two-stage crosslinking process.
[0103] For each of the three batches 25 g of pork-rind gelatin (300 g Bloom), 9 g of an 85 wt. % glycerine solution and 66 g of distilled water were mixed and the gelatin was dissolved at a temperature of 60° C. After ultrasonic degassing of the solutions, for carrying out the first crosslinking step an aqueous formaldehyde solution (2.0 wt. %, room temperature) was added, namely 3.75 g of this solution to batch A and 6.25 g of the solution to each of the batches B and C.
[0104] The mixtures were homogenized and applied at ca. 60° C. with a doctor blade in a thickness of ca. 250 μm onto a polyethylene support.
[0105] After drying at 30° C. and a relative atmospheric humidity of 30% for approximately one day, the films were removed from the PE support and further dried for ca. 12 hours under the same conditions. For carrying out the second crosslinking step, the dried films (thickness ca. 50 μm) were exposed in a desiccator to the equilibrium vapour pressure of a 17 wt. % aqueous formaldehyde solution at room temperature. In the case of films A and B the time of exposure to the formaldehyde vapour was 2 hours, in the case of film C 17 hours.
[0106] Of the formed bodies thus produced, film A on the whole has the lowest degree of crosslinking and film C on the whole the highest degree of crosslinking, with film B lying in between. This is reflected in the different degradation behaviour of the films, wherein the resorption times of the described films under physiological conditions in the animal experiment (see below) are between ca. 14 days (film A) and ca. 21 days (film C).
Confirmation of the Angiogenesis-Promoting Effect in the Animal Experiment
[0107] The angiogenesis-promoting effect of the gelatin films A, B and C in vivo was investigated in the animal experiment. As test animals, 10-week old mice of the strain Balb/C of the company Charles River (Sulzfeld) and having a body weight of 20 g were used.
[0108] As substrates, 5×5 mm 2 pieces of the previously described gelatin films were used in each case. In each case two film pieces of a specific degree of cross-linking were implanted in the mice subcutaneously in the region of the back of the neck. For this purpose, the animals were anaesthetized and the fur at the back of the neck was shaved off. Using forceps a piece of the neck skin was lifted and a ca. 1 cm long incision was made. Through this incision blunt forceps were used to create a subcutaneous pocket, into which two each of the film pieces were inserted using forceps. The wound was closed by means of two single-button sutures.
[0109] After 12 days the animals were killed and the angiogenetic effect of the implanted substrates was evaluated visually.
[0110] FIG. 7 shows as a negative control the corresponding region of the subcutaneous tissue of a mouse, in which no implantation of the angiogenesis-promoting substrate was carried out. Only a relatively slight interspersion with blood vessels is to be observed, as is normal for the subcutaneous skin tissue of the mouse.
[0111] FIGS. 8 a to 8 c show photographs of the subcutaneous skin tissue in the region of the implanted film pieces A, B and C after the corresponding mice were killed 12 days after implantation. The position of the film pieces is marked by black squares (reference character A, B or C for the corresponding film), as the films themselves are hard to see in the photographs. By way of experiment some of the films were dyed with Coomassie Brilliant Blue, as may be seen in FIG. 8 a.
[0112] All three images reveal a markedly increased generation of blood vessels in the area surrounding the implanted film pieces. Both the number and the size of the blood vessels are markedly greater than in the negative control in FIG. 7 . This result proves that angiogenesis may be locally stimulated by means of a material based on crosslinked gelatin that is resorbable under physiological conditions.
[0113] This local angiogenesis-promoting effect of materials based on crosslinked gelatin leads, in the vascular stent according to the invention, to a particularly advantageous effect. The layers of gelatin-containing material stimulate the generation of collateral blood vessels in the region of the vessel treated with the stent, so that in the event of restenosis, for example after the complete detachment of all of the layers, the risk of a cardiac infarction may be markedly reduced.
Example 3
Time-Dependent Separation Behaviour of a Plurality of Layers of a Gelatin-Based Material
[0114] In order to enable qualitative and quantitative determination of the time-dependent separation behaviour of a plurality of layers of a material based on crosslinked gelatin, the test described below was carried out.
[0115] In order to facilitate visual evaluation, the carrier used here was not a lattice frame of a stent but a flat polyethylene support, onto which two layers of the resorbable material were applied over a large area. Resorbable materials of the same composition may be applied within the framework of the present invention onto the surface of a carrier of a vascular stent according to the invention.
[0116] In order to be able to see the difference between the two layers of the resorbable material in the test, the first layer was dyed with a white pigment (titanium dioxide) and the second layer with a red food dye (Candurin Wine Red). For the same reason, layers of a greater thickness than the thicknesses preferred within the framework of the stent according to the invention were manufactured.
[0117] A first test batch 3-1 was carried out as follows:
[0000] 20 g of pork-rind gelatin (300 g Bloom), 8 g of glycerine, 1 g of titanium dioxide and 69 g of distilled water were mixed and the gelatin was steeped for 30 minutes at room temperature. Then the gelatin was dissolved by heating the mixture to 60° C. and the solution was homogenized and ultrasonically degassed.
[0118] This gelatin solution was applied by a doctor blade in a thickness of ca. 550 μm onto a flat polyethylene carrier in order to form the first layer of resorbable material on the carrier.
[0119] For carrying out a crosslinking of the gelatin, the polyethylene carrier having the first layer was exposed in the desiccator to the equilibrium vapour pressure of a 10 wt. % aqueous formaldehyde solution for 17 hours at room temperature.
[0120] Because the formaldehyde vapour is able to penetrate into the layer of resorbable material substantially only from the side remote from the carrier, a degree of crosslinking of the gelatin that decreases in the direction of the carrier is obtained by this method.
[0121] The first layer of the gelatin-based material was then dried overnight at 26° C. and a relative atmospheric humidity of 10%. The dried layer had a thickness of ca. 100 μm.
[0122] The carrier having the crosslinked first layer was cooled to ca. 4° C. To produce a separating layer, a Boeson releasing wax was sprayed onto the layer and spread evenly using a soft cloth.
[0123] The gelatin solution for the second layer of resorbable material was manufactured in the same way as the solution for the first layer, wherein 20 g of gelatin, 4 g of glycerine, 73 g of distilled water and, instead of titanium dioxide, 1 g of Candurin Wine Red were used as starting materials.
[0124] The resulting gelatin solution was applied likewise in a thickness of ca. 550 μm onto the first layer of resorbable material provided with the releasing wax.
[0125] The second layer was subjected likewise to crosslinking with formaldehyde vapour, as described for the first layer, only with the difference that the time of exposure to the crosslinking agent was only 2 hours instead of 17 hours. Consequently, the second layer has a lower average degree of crosslinking than the first layer, wherein the degree of crosslinking of the gelatin decreases within the second layer likewise in the direction of the carrier.
[0126] Drying was effected in the manner described for the first layer. After drying, the second layer had a thickness of ca. 70 μm.
[0127] The time-dependent separation behaviour of the two layers of gelatin-based material under physiological conditions was determined by incubation in PBS buffer (pH 7.2) at 37° C. By means of these physiological standard conditions it is possible to reconstruct the conditions such as prevail during use of the vascular stent according to the invention in the body.
[0128] FIG. 9 shows photographs of the carrier having the two layers according to the test batch 3-1 after 5, 6, 7, 10, 11 and 12 days of incubation in the PBS buffer.
[0129] As may be seen in the top three photographs, between the 5 th and 7 th day of incubation the neutralisation of the adhesion of the second (outer) layer and the separation of this layer from the first layer situated underneath occurs. The originally red-dyed second layer appears in the top three photographs of FIG. 9 as a dark area, while the white-dyed first layer is visible as a markedly lighter area. After 5 days ca. 20% of the second layer has separated and individual white specks of the first layer are visible. After 6 days ca. 65% of the second layer has separated, the second layer being present substantially only in the bottom right area of the carrier. After 7 days of incubation the second layer has finally substantially completely separated. Over the entire area of the test batch the first layer is now visible, wherein this layer is in part already swollen and blistering but is substantially still intact.
[0130] The separation of the first layer of gelatin-based material from the carrier occurs substantially between the 10 th and 12 th day of incubation, as may be seen in the bottom three photographs of FIG. 9 . In the course of separation of the first layer (white area) the polyethylene carrier becomes visible as a dark background. After 10 days of incubation ca. 35%, after 11 days ca. 80% and after 12 days ca. 95% of the first layer has separated from the carrier.
[0131] The described result demonstrates that with a plurality of layers of a resorbable material based on crosslinked gelatin it is possible by means of different average degrees of cross-linking in the individual layers to achieve control of the separation behaviour to the effect that the in each case outer layer has substantially completely separated before separation of the layer underneath begins. By virtue of this effect it is possible in the case of the vascular stent according to the invention to achieve a repeated renewal of the stent surface as a result of the successive separation of a plurality of layers of a resorbable material.
[0132] The test also further demonstrates that by neutralising the adhesion between the layers of the gelatin-based material an, at least in sections, two-dimensional separation of a layer from the layer below or from the carrier occurs. This is promoted by a lower degree of crosslinking of the gelatin at the inside of the respective layer.
[0133] A second test batch 3-2 was carried out in the same way as the previously described test batch 3-1, with the difference that the separating layer (Boeson releasing wax) between the two layers of the gelatin-based material was dispensed with. In this batch the first layer had a thickness of ca. 80 μm and the second layer a thickness of ca. 100 μm.
[0134] In the test batch 3-2 too, a sequential separation behaviour of the two layers was observed. However, in this case ca. 20% of the first layer had separated after 6 days of incubation, ca. 55% after 7 days of incubation and almost 100% only after 10 days of incubation.
[0135] The second layer of the batch 3-2 was still substantially intact after 13 days. After 18 days ca. 20% and after 25 days ca. 70% of the second layer had separated.
[0136] This result demonstrates in particular that through the use of separating layers the separation of individual layers from the layer below, given an identical degree of crosslinking of the gelatin, may be accelerated (second layer of batch 3-1 compared to batch 3-2). The later separation of the first layer of batch 3-2 may be ascribed to its having a greater thickness and being shielded by the separating layer.
[0137] A further test batch 3-3 was carried out in the same way as batch 3-2, with the difference that 2 ml of a 1 wt. % aqueous formaldehyde solution was added in each case to the gelatin solutions for the first and second layer prior to application by a doctor blade. As a result of this two-stage crosslinking both layers of this batch have a higher average degree of crosslinking compared to the batches 3-1 and 3-2. This led to a, once again, later separating time of the first layer of this batch, of which layer only less than ca. 5% had separated from the carrier after 25 days of incubation. Complete separation occurred only after 32 days.
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In order to provide a vascular stent, with which the risk of restenosis is reduced without having to use anti-proliferative active substances, there is proposed a carrier of a dimensionally stable material, as well as one or more layers, which are disposed at least in sections on the carrier, of a material based on crosslinked gelatin that is resorbable under physiological conditions, wherein the adhesion between the carrier and the layer and/or between individual layers can be neutralised.
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FIELD OF THE INVENTION
[0001] The present invention relates in general to a system and a method for purchasing one or more products and fulfilling purchase orders for the product or products. The invention pertains, more particularly, to an electronic system and method for receiving and managing one or more orders for one or more products, where a consumer generates an order that generates a response in both the retail and wholesale channels, and results in the consumer receiving an ordered product and the settlement of all opened accounts between the retailer and the wholesaler, in response to the consumer's purchase order.
BACKGROUND OF THE INVENTION
[0002] In the pet nutrition industry, veterinarians typically recommend, endorse and sell specialty pet nutrition products, either directly or through suppliers. This results in a highly controlled supply and distribution chain, whose maintenance ensures that the pet owner receive the specific and authentic product required by their pet.
[0003] Veterinarians maintain control over the conventional supply chain by stocking the requisite products, and overseeing their distribution and sale. While this seems practical, it requires the veterinarians to maintain large storage spaces capable for storing perishable products. They must also spend significant time running a store type operation. Many veterinarians lack such space and the desire to run a store type operation; however, with high profit margins from retail sales of such specialty products, most veterinarians want to sell and distribute these products as retailers. Also, being a retailer of specialty products generates good will for the veterinarian's practice.
[0004] As the consumer base continues to grow and move farther away from veterinarians, it is not always feasible for these consumers to travel to obtain their specialty nutrition products for their pets. Moreover, a pet owner, who travels to their veterinarian, depends on that particular veterinarian's inventory being adequately stocked with the desired specialty products in the desired amounts.
[0005] Other industries maintain control over their supply chains, and in particular, allow only authorized retailers to sell the product. For example, U.S. Patent Publication US 2003/0050857 A1 discloses an electronic commerce marketing system, where a consumer places an electronic order with a supplier over the supplier's web site. The supplier then directs the order to a field service representative or salesperson, who sells the ordered product to the consumer for the retail price. The field service representative purchases the product at any time from the supplier, and carries the product in his inventory, regardless of whether the product has been ordered by a consumer.
[0006] Additionally, professional activities, such as retail sales by certain retailers, are legally regulated. This is especially true for health professionals, and in particular, licensed animal health professionals. For example, California prohibits veterinarians from receiving commissions from any referrals they make, including referrals of products. As a result, veterinarians must be extremely careful when offering products for sale to consumers.
SUMMARY OF THE INVENTION
[0007] The system and method of the invention improves on conventional ordering and purchasing processes, as it does not require a retailer, such as a veterinarian, to maintain an inventory of product. The sales do not require physical handling of product, nor do they involve logistics for moving product, on the part of the retailer.
[0008] In particular, the present invention is applied to transactions that begin when a pet owner, either independently or through the recommendation from a veterinarian, orders a product, and culminates in the pet owner receiving the ordered product. The product is ordered through an ordering system that matches the pet owner and the veterinarian. In particular, the ordering system includes veterinarian retailer web sites, from which the product is ordered from the supplier. All orders placed on these veterinarian retailer web sites are subject to approval of the veterinarian retailer.
[0009] The system and method improve on conventional ordering and purchasing processes, for example, for specialty pet nutrition products, whose supply and distribution chain is highly controlled, as participants in the supply and distribution chain are approved and may be licensed. The highly controlled nature of the supply and distribution chain includes retail sales through participating veterinarian retailers, who are authorized by the supplier, and active participation of these selected veterinarian retailers in making the sales, coupled with home delivery of the product from a supplier of authentic product. In this manner, only the proper and authentic product reaches the consumer.
[0010] The present invention also includes methods for selling products through professionals, such as health professionals, whose sales activity may be legally regulated. The present invention provides systems and methods for sales activity of specialized products by licensed health professionals, where the professional sells products without maintaining an inventory or receiving a commission for the sales.
[0011] The present invention provides an electronic system and method for purchasing and fulfilling a product order between a consumer, who typically purchases the product as a retail buyer, a retailer, who sells the product, and a supplier, the wholesaler of the product. As a result of the invention, a consumer needing a specialty product sold through a highly controlled distribution chain, can electronically purchase the specialized product, and have it delivered to a desired location, in a single purchasing operation. The consumer must no longer travel to a specialized retailer, for example, a veterinarian. This eliminates the risk that the desired amount of product is not available in veterinarian's on-site inventory.
[0012] The present invention provides a method where retail orders and their corresponding wholesale orders are coordinated, to provide efficient settlement and distribution of funds to all parties involved. The consumer places the retail order for the product with a veterinarian retailer, the processing of the retail order and corresponding wholesale order, and shipment of the product, are transparent to the consumer. As a result of this transparency, the consumer sees only the delivered product and a corresponding charge on a credit card statement.
[0013] The invention is directed to a method for managing an order for a product. The method includes, receiving electronic input corresponding to at least one order for the product, electronically placing a first order with a financial agent based on the received at least one order, and, electronically placing a second order with a supplier based on the received at least one order. Funds corresponding to the at least one order are electronically received, and at least a portion of these received funds are electronically transferred to the supplier.
[0014] Another embodiment of the invention is directed to an apparatus for managing orders for a product. The apparatus is, for example, controlled by a supplier of a product, who will receive the wholesale price for the product upon its sale by a retailer. The apparatus includes a first component for supporting a web site of at least one retailer, for example, a supplier-authorized veterinarian, over which at least one order for the product can be placed, a second component for receiving the at least one order for the product from the web site, and, a third component, linked with the second component. The third component functions to place a first order corresponding to the at least one order for the product to a financial agent, and to place a second order corresponding to the at least one order for the product to a supplier. There is also a fourth component for causing settlement of funds between a component that receives funds from the first order and a component that receives funds for the supplier.
[0015] Another embodiment of the invention is directed to a method for managing an order for a product. The method includes electronically receiving at least one order for the product from a buyer, for example, a retail buyer. A first order is placed with a financial agent based on the received at least one order; and a second order is placed with a supplier based on the received at least one order. The method also includes receiving funds corresponding to the at least one order, and transferring at least a portion of the received funds for the at least one order to the supplier.
[0016] Another embodiment of the invention is directed to a method for managing an order for a regulated product (whose sales are controlled, typically by statute or the like), where the product to be purchased by a buyer is determined based on a consultation with an entity authorized to order the regulated products from a supplier (e.g., an approved veterinarian retailer). An electronic order for the determined product is created by sending a first segment of the order, or first data associated with the electronic order, to a financial agent, and sending a second segment of the order, or second data associated with the electronic order, to the supplier. Funds are received from the financial agent that correspond to the first segment of the electronic order. The product associated with the second segment of the electronic order is shipped to the buyer, and, at least a portion of the received funds are transferred to the supplier, that correspond to the amount of the product sold, typically at the wholesale price, in the electronic order.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Attention is now directed to the attached drawings, where like numerals or characters indicate corresponding or like elements. In the drawings:
[0018] FIG. 1 is a diagram of an exemplary system showing the ordering process in accordance with an embodiment of the invention;
[0019] FIG. 2 is a diagram of the exemplary system of FIG. 1 , showing the components associated with an embodiment of the invention after the order has been placed;
[0020] FIGS. 3A-3D are a flow diagram showing a process of order purchasing and fulfillment in accordance with an embodiment of the invention; and
[0021] FIGS. 4-9 are diagrams of phases of a method in accordance with an embodiment of the invention.
DETAILED DESCRIPTION
[0000] 1. System
[0022] The present invention is directed to systems and methods or processes for order purchasing and fulfillment at the consumer (buyer) and supplier levels, and corresponding retail and wholesale levels, respectively. The process is typically an electronic process over networks, such as the Internet, allowing multiple, geographically dispersed consumers, to purchase products from a tightly controlled distribution chain.
[0023] The ordering phase of the process is controlled. In particular, the consumer's order of the product is through a retailer, such as a licensed veterinarian retailer, or based upon the recommendation of the veterinarian retailer. The veterinarian retailer is authorized to sell the product by the supplier, who is the wholesaler of the product. Orders are placed through a web site of the veterinarian retailer, and are subject to approval of the veterinarian retailer. The veterinarian retailer and the supplier are electronically linked, over a network, such as the Internet, to expedite ordering and ultimate delivery of the ordered product to the consumer.
[0024] The process begins as a consumer, for example, a retail buyer or buyer (or purchaser), places a retail order for product with a veterinarian retailer. The veterinarian retailer has been authorized to sell the product by the supplier, who is typically the wholesaler of the product. The consumer places a retail order on a retailer's web site, either directly or through an agent. The consumer's retail order is translated into an electronic order, for processing over a network, such as the Internet. Placement of the electronic order sends a retail order for processing along a first channel, and a wholesale order for processing along a second channel. The retail and wholesale orders are placed contemporaneous in time, and are transparent to the consumer, who ordered the product.
[0025] Upon authorization of the consumer's credit card, the process is initiated to deliver the ordered product to the consumer. Contemporaneous with authorization, the consumer's credit card is settled and the retailer receives the retail price for the order. The wholesale price is paid to the supplier, who ships the ordered product to the consumer, and the retailer retains the difference between the retail and wholesale price (minus service charges) in a final settlement between the retailer's financial institution and the supplier.
[0026] During this process, title of the product transfers to the veterinarian retailer from the supplier, once the retail order has been approved and it has been received by the supplier, but before it is shipped to the consumer. However, the veterinarian does not maintain a physical inventory of the product at any time during the process.
[0027] FIG. 1 shows the order process on an exemplary system 20 . The system 20 includes a network, for example, the Internet 22 , and a home server (HS) 24 associated with the supplier or wholesaler. The home server (HS) 24 supports its own web site (HS 1 ) 26 and may support retailer web sites (S 1 -Sn) 30 a - 30 n, either internally as shown, or externally, over the network, through which the supplier or wholesaler's product is sold. The retailers are, for example, veterinarians, that the supplier has authorized to sell the product over the individual veterinarians' web sites (S 1 -Sn) 30 a - 30 n, that the supplier supports (for example, at the supplier's home server (HS) 24 ).
[0028] Product ordering occurs through two exemplary consumers, who are, for example, retail buyers or buyers, indicated as C 1 and C 2 . Consumer C 1 places an order, for example, a retail order, in a traditional manner, such as telephone, facsimile (fax), walkup, postal mail, or electronic mail (e-mail). Consumer C 2 places an order, for example, a retail order, electronically, over a network, such as the Internet.
[0029] A consumer, for example, the consumer indicated as C 1 , may contact the supplier directly, typically at a supplier's call center (CC) 34 , by telephone 35 . Since the product is only sold at the retail level through veterinarian retailers, the consumer's (C 1 ) attempted order, will be referred to a web site (S 1 -Sn) 30 a - 30 n of a veterinarian retailer who handles this product. Alternately, the agent at the call center (CC) 34 enters the consumer's (C 1 ) order, for example, a retail order, on the veterinarian's web site, for example, site S 1 30 a, for the veterinarian of the particular consumer. The call center (CC) 34 is linked to the home server (HS) 24 and accordingly, to the veterinarian web sites (S 1 -Sn) 30 a - 30 n. The veterinarian web sites (S 1 -Sn) 30 a - 30 n, all include electronic commerce (e-commerce) modules to permit order placement and ordering, for example, at the home server (HS) 24 .
[0030] Alternately, from the call center CC 34 , the consumer C 1 may be directed to the veterinarian (V) 36 , either by telephonic transfer or a referral. The ordering process would continue as detailed immediately below.
[0031] The consumer C 1 may also contact their regular veterinarian, for example, a veterinarian (V) 36 . The veterinarian (V) 36 may take the consumer's order by telephone, fax, walk-up, postal mail, or electronic mail or the like, and transfer it to their web site (the veterinarian (V) 36 is linked to their web site), here, for example, site S 1 30 a, for this particular veterinarian retailer.
[0032] Alternately, the orders for product may be made electronically, as shown by a consumer, indicated as C 2 , at their computer 38 . In a first instance, the consumer C 2 may desire to purchase product from the supplier's web site (HS 1 ) 26 . The supplier's web site (HS 1 ) 26 , prompts the consumer C 2 to select their veterinarian, by numerous searching parameters, such as name, address, city, zip code, telephone numbers. Once the veterinarian is located, the consumer C 2 is directed to the veterinarian's web site, here, for example, the web site S 1 30 a. If the consumer C 2 is a new customer, then their product selection is typically subject to a participating veterinarian's approval (typically through a consultation with the veterinarian to determine the specific product to be ordered).
[0033] The consumer C 2 may also place their electronic order with the veterinarian's web site (provided they are an approved customer of the particular veterinarian based on a consultation with the veterinarian to select the specific product for their pet) by accessing this site, for example, site S 1 30 a, directly. This access typically includes directing their web browser in their computer 38 to the address of the veterinarian's web site.
[0034] The order (for example, a retail order) that has been placed, ultimately at the individual veterinarian's web site, typically includes, the consumer's name, address, telephone number, credit card number, billing address, shipping address and veterinarian name. The order now resides at the individual veterinarian's web site, for example, the site (S 1 ) 30 a, for processing in accordance with process (method) of FIGS. 3A-3D .
[0035] FIG. 2 shows the system 20 , and in particular, the components associated with processing and fulfilling the consumer's order. All of the components described below are electronically linked to other components or the network, for example, the Internet 22 , by links. These links are wired, wireless, or combinations thereof, and may be single or multiple.
[0036] The home server (HS) 24 , here, for example, associated with the supplier, is linked to the veterinarian web site (S 1 ) 30 a, either directly (in broken lines) or through the Internet 22 . The home server (HS) 24 is also linked to a warehouse agent 40 , along a private, and preferably secure link. The warehouse agent 40 includes components for billing, shipping and sending shipping advices to the requisite components of the system 20 . The home server (HS) 24 is linked to the Internet 22 .
[0037] A third party veterinarian agent 44 , here, for example, associated with the veterinarians' web sites (S 1 -Sn) 30 a - 30 n, is linked to the Internet 22 . This third party veterinarian agent 44 is a financial transaction handler or financial agent, that is typically independent of the enterprises controlling the home server (HS) 24 and the veterinarian or retailer web sites (S 1 -Sn) 30 a - 30 n. This third party veterinarian agent 44 typically includes components for processing credit cards on behalf of the veterinarian or retailer web sites (S 1 -Sn) 30 a - 30 n, and components for the financial transactions associated with the credit cards as well as directing payments and settling accounts. The third party veterinarian agent 44 is linked to a financial institution 46 of the individual veterinarian (who owns or controls the web site (S 1 ) 30 a ). This link is typically a private and secure link. In a normal operation, the third party veterinarian agent 44 is linked to multiple individual veterinarian web sites. The third party veterinarian agent 44 is also set up as a merchant with a third party payment processor 48 that processes electronic credit card payments.
[0038] The third party payment processor 48 is linked to the Internet 22 . It includes components for authorizing credit cards and directing payments to the requisite recipients. The third party payment processor 48 is linked to financial institution(s) 50 , typically over a private and secure link(s).
[0039] Turning also to FIGS. 3A-3D , an exemplary process of order placement and fulfillment will now be described. This description will also make reference to components detailed in FIGS. 1 and 2 .
[0040] The process begins as a retail order is placed at the web site of an individual veterinarian, at block 102 . The order is ultimately placed through the web site (S 1 ) 30 a of a particular veterinarian, for a particular product(s). The actual order, as discussed above, can be placed on the veterinarian's web site (S 1 ) 30 through a call center agent (CC) 34 , who places an order that was attempted through the supplier, the veterinarian or their staff, or by a consumer C 2 (retail purchaser) who has accessed the web site (S 1 ) 30 a of his veterinarian over the Internet 22 . This retail order is input into databases of the homer server (HS) 24 . With the input received, the consumer's credit card is now subjected to an authorization process.
[0041] At block 104 , the veterinarian's web site, for example, web site (S 1 ) 30 a, sends a request to the third party veterinarian agent 44 to obtain authorization to charge the consumer's credit card. The third party veterinarian agent 44 then passes this request to a third party credit card processor, such as the third party processor 48 , at block 106 . The third party veterinarian agent 44 is previously set up as a merchant with the third party processor 48 . The third party processor 48 is typically an organization associated with a financial institution.
[0042] The third party processor 48 sends an authorization request to the financial institution, for example, the financial institution 50 , that issued the credit card to the consumer, at block 108 . The financial institution 50 determines if the monetary charge by the consumer for the product is acceptable, at block 110 . If the charge is not acceptable, the process ends, at block 112 . This end of the process may include a message sent to the veterinarian's web site (S 1 ) 30 a (through the third party processor 48 and third party veterinarian agent 44 ) that the credit card was denied. The veterinarian may inform the consumer of this denial, by electronic mail or other conventional notification method.
[0043] If the charge is acceptable, the process moves to block 114 , where the credit card issuing financial institution 50 issues an authorization to the third party processor 48 , that the monetary charge made by the consumer is acceptable. At block 116 , the third party processor 48 issues an authorization number to the third party veterinarian agent 44 . This authorization number is, in effect, a guarantee of payment to the third party veterinarian agent 44 . The third party veterinarian agent 44 receives the authorization number, and sends a credit card authorization to the veterinarian's web site (S 1 ) 30 a, at block 118 .
[0044] The phase of the process detailed by blocks 104 - 118 , where the consumer's credit card is authorized for the amount of the purchase of product, is transparent to the consumer. With the consumer's credit card authorized for the consumer's retail order of the product, the veterinarian's web site (S 1 ) 30 , places a wholesale order, that is similar and typically identical in all aspects, except price, to the consumer's retail order, and the next phase of the process begins.
[0045] Specifically, at block 120 , the veterinarian web site (S 1 ) 30 a places a wholesale order with the supplier of the product. The wholesale order includes the consumer's shipping information. The supplier, through rules and policies at the home server (HS) 24 or other server(s) associated with ordering and shipping, determines whether to accept the wholesale order, at block 122 . If the order is not accepted, the process ends at block 124 . The activity at block 124 is similar to that described for block 112 above.
[0046] If the order is accepted, the process moves to block 126 . Within this block, two sub processes occur, typically contemporaneously and may occur simultaneously. In one sub process, the supplier invoices the veterinarian for the wholesale order, by sending an electronic communication to the third party veterinarian agent 44 , and the supplier debits its accounts receivable (for example, a database inside the home server (HS) 24 or other device performing financial applications for the supplier). In the other sub process, the supplier sends the order information with shipping instructions to its warehouse agent, for example, the warehouse agent 40 .
[0047] The warehouse agent 40 receives the order information and shipping instructions, and transfers the ordered product (by the consumer C 2 ) from its inventory, to the individual veterinarian's inventory (from whose web site the product was ordered), at block 128 . In making this transfer, title for the product transfers from the supplier to the individual veterinarian. Accordingly, the individual veterinarian owns the product at the time it is delivered to the consumer. The inventory transfer is electronic, in a database or the like, as the veterinarian does not maintain a physical inventory.
[0048] The processing of the retail order, in blocks 104 - 118 , and the processing of the corresponding wholesale order, in blocks 120 - 128 , are typically contemporaneous in time.
[0049] In the next phase of the process, the product is shipped from the warehouse of the warehouse agent 40 to the consumer. The process now moves to block 130 , where the shipment occurs and the warehouse agent 40 electronically sends a shipping advice, over the Internet 22 to the third party veterinarian agent 44 , indicating that the order has been shipped. The shipping advice typically includes information as to the carrier used to transport the product to the consumer, departure and estimated arrival times, the carrier name, and the like.
[0050] As the third party veterinarian agent 44 is linked to the veterinarian's web site (S 1 ) 30 a over the Internet 22 , the consumer C 2 can access this shipping advice through the veterinarian's web site (S 1 ) 30 a, through the web browser of the consumer's (C 2 ) computer 38 over the Internet 22 . This phase of the process is also transparent to the consumer C 2 .
[0051] In the next phase of the process, the consumer's credit card is settled and the veterinarian receives the retail price for the product sold to the consumer. The process now moves to block 140 , where the third party veterinarian agent 44 , upon receiving the shipping advice, sends a credit card settlement request to the third party processor 48 , over the Internet 22 . At block 142 , with the credit card settlement request received, the third party processor 48 orders payment to the third party veterinarian agent 44 for the retail price for the sale of the product. In turn, the third party veterinarian agent 44 orders payment to the third party processor 48 of a service charge, at block 144 .
[0052] The process moves to blocks 146 , 147 and 148 contemporaneously, and the sub processes detailed in blocks 146 and 147 , and block 148 , can be performed in any order. In block 146 , the third party processor 48 sends a settlement request to the credit card issuing financial institution 50 . In response to receiving the settlement request, at block 147 , the credit card issuing financial institution 50 pays the third party processor the retail price of the product purchased by the consumer, minus an interchange fee.
[0053] At block 148 , the third party veterinarian agent 44 has received the funds for the retail sale from the third party processor 48 . The agent authorizes the deposit of these finds into the third party veterinarian agent's 44 financial institution, for example, the financial institution 46 .
[0054] From blocks 147 and 148 , the process moves to block 150 . At this block, the consumer's (for example, the consumer C 2 ) credit card, from which he made the retail purchase of product, is billed. In the credit card invoice, the billing charge line or merchant charge line may include an identity line that is common to the retailer veterinarian and the supplier, but not unique to just one of them.
[0055] The final phase of the process involves the supplier receiving the wholesale price from the retailer. With the process having now moved to block 160 , the third party veterinarian agent 44 instructs the financial institution 46 , through electronic communications, to pay to the supplier the wholesale price of the product sold that day. The remainder of the funds (based on the retail price) goes to the veterinarian (typically, their bank account) from whose web site the retail sale was made. While a daily settlement is indicated, the settlement may be any other predetermined time, such as every other day, weekly or even monthly, depending on the desires of the supplier and the veterinarians. These funds may be transferred in accordance with conventional financial transfer methods.
[0056] Additionally, within the normal credit card grace period, the consumer C 2 , will pay the retail price to the credit card issuing financial institution 50 .
[0057] The process ends at block 170 . The process can be repeated for as long as desired, and for as many retailers who have web sites supported by the home server (HS) 24 .
[0058] In the system and method described above, where funds are transferred between parties and/or accounts corresponding to parties, transfer of funds is accomplished by conventional funds transferring methods. These methods may include Electronic Funds Transfer (EFT).
[0059] While the methods and systems are described above for veterinarians, the methods and systems may be applied to other professionals or specialized retailers, where the consumer has a first consultation with the professional or specialized retailer, prior to purchasing the product recommended by the professional or specialized retailer. The product purchased from the professional or specialized retailer, is shipped directly to the consumer from the supplier, such that the professional or specialized retailer does not maintain a physical inventory of the product. Additionally, the supplier maintains a group of informed consumers for its exclusive products.
[0000] 2. Method
[0060] The present invention also provides a method for fulfilling and managing product orders. The method allows a consumer or buyer, to purchase products from a supplier, that were previously only available to the consumer or buyer through purchase and pick up at approved or licensed retailers. The method allows for a consumer or buyer to purchase the desired product from the supplier, through a supplier-approved retailer approving the purchase. The consumer or buyer receives their product delivered to their desired address, for example, their home, from the supplier. The method involves orders for product that travel through both the retail and wholesale channels. However, the order movement along the retail and wholesale channels is transparent to the consumer or buyer, who places a retail order through a supplier-approved retailer, and receives the desired product from the supplier, delivered to his desired address, with his credit card being charged for the retail price of the order. The method disclosed may, for example, be performed on the system 20 detailed above, and shown in FIGS. 1-3D .
[0061] FIGS. 4-9 show the method of the invention, as applied to a specialized product from a supplier, and a supplier authorized and approved veterinarian retailer. The method is illustrated in a series of diagrams. Each diagram is directed to a phase of the method.
[0062] FIG. 4 shows the first phase of the method. In this phase, a consumer or buyer places a retail order for the product of a supplier through a retailer. The retailer must approve the purchase, as the product may be such that its sale and distribution is highly controlled. The retailer may, for example, be a veterinarian, who is approved and authorized by the supplier to sell the supplier's product, to consumers they have approved. The approval to sell a specific product carried by the supplier to the individual consumer or buyer, may be made through a consultation, between, for example, the veterinarian retailer and the consumer. In this phase, the veterinarian retailer does not maintain any physical inventory of product, but merely serves as an approved ordering point for the consumer to obtain product from the supplier, who maintains all physical inventory of product until the product is shipped to the consumer (or buyer), as detailed below.
[0063] The consumer (or buyer) 302 will make a retail product order, that will ultimately be placed through a web site 304 of an individual veterinarian. The individual veterinarian is approved by the supplier to be a retailer for the product. The individual veterinarian web sites 304 are typically hosted by the supplier, and include e-commerce modules that enable consumers 302 to place orders through the web sites. For purposes of explanation, the veterinarian web site 304 is representative of all veterinarian web sites supported by the supplier, and who are authorized by the supplier to be retailers of the supplier's product(s).
[0064] Consumer purchasing may occur, for example, through four typical scenarios. The first two scenarios occur as the consumer 302 may contact the supplier 306 , either conventionally, over the telephone, such as through a toll-free telephone number (for example, telephone numbers having the digits 800, 866, 877, 888), or electronically, over a network such as the Internet.
[0065] In the case of telephonic inquiries, as the supplier 306 does not handle direct sales from individual consumers 302 , a supplier representative will assist the consumer 302 in placing their order. The assistance will be such that the consumer 302 is referred to their veterinarian's web site 304 , where the representative enters the consumer's order at the veterinarian's web site 304 . Alternately, if the consumer 302 does not have a veterinarian, the representative assists the consumer 302 with selecting a veterinarian, and placing their order as detailed above. Additionally, the consumer 302 , once directed by the representative to the requisite veterinarian's web site 304 , can place their order electronically, by themselves, by following on-screen prompts at the web site 304 . As the product's sale and distribution chain is highly controlled, all orders placed at the individual veterinarian's web site 304 are subject to approval by the veterinarian associated with the web site.
[0066] In the case of electronic orders, the consumer 302 may access the web site of the supplier 306 . As the supplier 306 does not handle direct sales from individual consumers, the inquiring consumer 302 will be prompted on their monitor, to select their particular veterinarian. Prompting is such that veterinarians may be searched by numerous parameters, including name, address, telephone number, and other search parameters. If a veterinarian is selected, the consumer (consumer's browser) will be directed to the veterinarian's web site 304 , with the order placement as detailed above.
[0067] If the consumer 302 does not have an existing relationship with a veterinarian, or can not find their veterinarian from the web-based search, the search parameters entered may be used to assist the consumer 302 in selecting a veterinarian, with a supplier-approved web site, to place their order. Once the consumer 302 arrives at the chosen veterinarian web site 304 , their order may be placed on the web site 304 as detailed above. In this case, the order placed at the veterinarian's web site 304 must be approved by the veterinarian.
[0068] In another ordering scenario, consumers 302 may go to their veterinarian's web site 304 , and place an electronic order directly at the web site 304 (as detailed above). Ordering in this manner is typically operational at all times.
[0069] Another ordering scenario is along more conventional techniques, where the consumer 302 , places their order with their veterinarian, through the veterinarian's office 308 . The order is typically placed by conventional methods, such as a personal visit (walk-up), telephone, facsimile, electronic mail, or the like, to the veterinarian's office. If the veterinarian has the product on hand, the consumer can purchase the product from the veterinarian's office 308 on a cash and carry basis. As this is typically not the case, or if the consumer would like home delivery of the product, the veterinarian's staff or the like (or the veterinarian), enters the consumer's order on the veterinarian's web site 304 , as detailed above.
[0070] A second phase of the method is now described. This second phase begins as retail product orders are received at the veterinarian's web site 304 . From the web site 304 , a retail order and a parallel wholesale order are made. FIG. 5 illustrates the retail channel for the order, as the consumer's credit card is authorized for the consumer's retail purchase of the product.
[0071] The veterinarian web site 304 places a credit card authorization request with a third party veterinarian agent 312 . This request is such that the third party veterinarian agent 312 obtains authorization to charge the consumer's credit card for the retail price of the product ordered. The third party veterinarian agent 312 is a financial agent, typically independent of the enterprises controlling the ordering of the product. The third party veterinarian agent typically handles credit card processing for all veterinarians, whose web sites are associated both with it and the supplier. Additionally, the third party veterinarian agent 312 is typically set up as a merchant for credit card transactions.
[0072] The third party veterinarian agent 312 , having received a credit card authorization request, will send a similar credit card authorization request to a third party processor (for credit cards) 314 . This third party processor 314 may be a service provider, for example, Paymentech® electronic payment processing. The third party processor 314 then sends an authorization request to the financial institution 316 , that issued the consumer's credit card, that is being used for this retail purchase.
[0073] The credit card issuing financial institution 316 determines if the charge in the authorization request is acceptable. If it is not, the method terminates, and the consumer 302 is notified that the attempted charge is not acceptable. If the charge is acceptable, an authorization is issued to the third party processor 314 . The third party processor 314 issues and sends an authorization number for this retail transaction (sale) to the third party veterinarian agent 312 . This authorization number typically serves as a payment guarantee for the third party veterinarian agent 312 . With the authorization number received from the third party processor 314 , the third party veterinarian agent 312 sends an authorization to the veterinarian's web site 304 .
[0074] The next phase of the method begins, as shown in FIG. 6 , where the veterinarian places the wholesale order for the product with the supplier. The wholesale order is over a separate channel, between the veterinarian web site 304 and the supplier 322 of the product, for which the order has been placed.
[0075] Initially, once the veterinarian web site 304 has received an approved credit card authorization, from the third party veterinarian agent 312 , the consumer's order is considered to be accepted (along with any other rules and policies of the particular veterinarian who controls the web site necessary to authorize a retail sale to the particular consumer). With this acceptance, the veterinarian web site 304 places a wholesale order for the product with the supplier 322 . This wholesale order typically includes the shipping information for the consumer 302 who made the order.
[0076] The supplier 322 , if the wholesale order is accepted, invoices the individual veterinarian (from whose web site they received the wholesale order), for the wholesale order and debits their accounts receivable. The supplier 322 also sends the order information with shipping instructions to its warehouse agent 324 . Upon receiving the order, the warehouse agent 324 transfers the ordered product from its inventory to the ordering veterinarian's inventory, and therefore, transferring the title for the ordered product from the supplier 324 to the veterinarian (from whose web site the sale was made).
[0077] FIG. 7 shows the next phase of the method, where the supplier ships the ordered product to the consumer for the veterinarian. The warehouse agent 324 now ships the ordered product to the consumer (buyer) 302 . Typically contemporaneous with the shipping, the warehouse agent 324 sends a shipping advice to the third party veterinarian agent 312 . This shipping advice indicates that the order of product has been shipped, the carrier, estimated departure time and estimated arrival (delivery) time. The information from this shipping advice is accessible by all parties, through the veterinarian's (from whom the sale was made) web site 304 .
[0078] The consumer's credit card is settled and the veterinarian receives the retail price for the sale in the next phase of the method, as shown in FIG. 8 . The third party veterinarian agent 312 , upon receiving the shipping advice, sends a credit card settlement request to the third party processor 314 . The third party processor 314 , upon receipt of the credit card settlement request, pays the third party veterinarian agent 312 the price for the retail sale. The third party veterinarian agent 312 pays the third party processor 314 , a merchant service charge, for the transaction.
[0079] The third party processor 314 then sends a settlement request to the credit card issuing financial institution 316 of the consumer's credit card used in making the order. The credit card issuing financial institution 316 typically pays the third party processor 314 the retail price, minus an interchange fee.
[0080] The third party veterinarian agent 312 , having received payment from the third party processor 314 , deposits the funds received as the payment into its account at a financial institution 332 . The credit card issuing financial institution 316 bills the credit card of the consumer 302 , for the retail price of the order, with the billing charge line or merchant charge line, that may include an identity line common to the retailer veterinarian and the supplier, but not unique to just one of them.
[0081] In the final phase, as shown in FIG. 9 , the wholesale price is paid to the supplier. The veterinarian, from whose web site the sale was made, retains the remainder of the funds. At a predetermined time, typically a nightly basis, the veterinarian agent's financial institution 332 , upon receiving an instruction (typically electronic) from the third party veterinarian agent 312 , will pay the supplier 322 the wholesale price of product sold by the veterinarian that day. The remainder of the price will be distributed to the veterinarian 342 (associated with the web site 304 from which the sale was made).
[0082] Additionally, the consumer 302 will pay the requisite funds for the credit card charge for the order, to the credit card issuing financial institution 316 . This payment is made within the normal grace period for the credit card, as per the credit card agreement between the consumer 302 and the credit card issuing financial institution 316 .
[0083] In the method described above, where funds are transferred between parties and/or accounts corresponding to parties, transfer of funds is accomplished by conventional funds transferring methods. These methods may include Electronic Funds Transfer (EFT).
[0084] The above described systems, methods and processes, including portions thereof, sub processes, etc., can be performed by software, hardware and combinations thereof. The methods and process, and portions thereof, can be performed by computers, computer-type devices, workstations, processors, microprocessors, other electronic searching tools and memory and other storage-type devices associated therewith. The process and portions thereof can also be embodied in programmable storage devices, for example, compact discs (CDs) or other discs including magnetic, optical, etc., readable by a machine or the like, or other computer usable storage media, including magnetic, optical, or semiconductor storage, or other source of electronic signals.
[0085] The systems, methods and processes, including components thereof, herein have been described with exemplary reference to specific hardware and software. The processes (methods) have been described as exemplary, whereby specific steps and their order can be omitted and/or changed by persons of ordinary skill in the art to reduce these embodiments to practice without undue experimentation. The systems, methods and processes have been described in a manner sufficient to enable persons of ordinary skill in the art to readily adapt other hardware and software as may be needed to reduce any of the embodiments to practice without undue experimentation and using conventional techniques.
[0086] While preferred embodiments of the present invention have been described, so as to enable one of skill in the art to practice the present invention, the preceding description is intended to be exemplary only. It should not be used to limit the scope of the invention, which should be determined by reference to the following claims.
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A system and method for managing product orders coordinates corresponding retail and wholesale orders, to provide efficient settlement and distribution of funds to all parties involved. The systems and methods disclosed do not require retailers to carry an inventory of products, and the processing of the retail order and its corresponding wholesale order, and shipment of the product, are transparent to the consumer or retail buyer. As a result of this transparency, the consumer sees only the delivered product and a corresponding charge on a credit card statement.
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This application is a continuation of application Ser. No. 308,430 now abandoned.
SUMMARY OF THE INVENTION
The present invention relates to games and, more particularly, to a word forming game that is easy to play by two or more players and to such a game that is extremely simple and educational for younger players.
The apparatus of the present invention includes a game board, a plurality of game pieces, a plurality of dice and a plurality of game cards. The game board is divided into a plurality of adjacent columns or lanes located intermediate a starting row and a finish row. The starting row contains a plurality of adjacent spaces which are consecutively numbered, whereas the finish row contains a corresponding plurality of spaces each of which contain a letter of the alphabet, which letters combine to spell the title of the game. Each column or lane contains a plurality of adjacent spaces that are in alignment with their respective starting row numbers and their finsih row letters. Dispersed at various predetermined ones of such adjacent spaces are commands or instructions which may have a strategic effect on the outcome of the game.
The game cards include a plurality of multi-card sets with the cards of each set thereof all containing one letter corresponding to the game-spelling letters of the finish row. The arrangement is such that the cards of the several sets contain duplicate letters which combine to spell the title of the game.
The object of the game is to use the cards to form any of the words that can be formed from the letters in the title of the game, including the title words as well. The first player to form any such word is the winner of the game. The game is, thus, extremely fast to play and will hold the attention and interest of any aged player. The manner of play and specific examples will follow hereinbelow.
Essentially, then, the present invention provides a word forming game apparatus which includes; a game board having a plurality of adjacent spaces arranged to form a plurality of columns or lanes; a starting row adjacent one edge of said lanes containing a plurality of consecutively numbered starting spaces with the number of which corresponding to the number of said lanes; and a finish row comprising a plurality of adjacent spaces along an opposite edge of said lanes, each individual space of which contains a letter of the alphabet that combines with the letters in the adjacent spaces to spell the title of the game.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the present invention and its characterizing features reference should now be had to the following detailed description thereof taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a top plan view of the game board of the apparatus of the present invention;
FIG. 2 is a top plan view of the game cards that are adapted to be used in playing the game of the present invention;
FIG. 3 is a pictorial view of the plurality of dice that are used in the game of the present invention; and
FIG. 4 is a pictorial view of exemplary game pieces that may be used in playing the game of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring in detail to the drawing FIGURES, the game board is generally depicted at 10 and is shown as comprising a starting row 12, a finish row 14 and a plurality of squrares or spaces 16 located therebetween. Starting row 12 includes a plurality of adjacent spaces 18 which may be consecutively numbered with the numerals 3 to 16, as viewed from left to right in FIG. 1. Other numerals may be employed, so long as they are consecutively numbered.
The finish row 14, similarly, includes a plurality of adjacent spaces 20; each of which being in alignment with their respective spaces 18 of the starting row. These spaces 20 each contain a letter of the alphabet and the adjacent letters are so arranged as to form the word or words of the title of the game. Thus, as depicted, if the game title is "MISSING LETTERS," then space 20 in alignment with the starting row number 3 contains the letter "M;" the space 20 in alignment with the starting row number 4 contains the letter "I;" the space 20 in alignment with the number 5 contains the letter "S;" the space 20 in alignment with the number 6 contains the letter "S;" the space 20 in alignment with the number 7 contains the letter "I;" the space 20 in alignment with the number 8 contains the letter "N;" the space 20 in alignment with number 9 contains the letter "G;" the space 20 in alignment with the number 10 contains the letter "L;" the space 20 in alignment with the number 11 contains the letter "E;" the space 20 in alignment with the number 12 contains the letter "T;" the space 20 in alignment with the number 13 contains the letter "T;" the space 20 in alignment with the number 14 contains the letter "E;" the space 20 in alignment with the number 15 contains the letter "R;" and the space 20 in alignment with the number 16 contains the letter "S;".
The spaces or squares 16 are arrayed into a plurality of columns or lanes (fourteen, as illustrated) located between the aligned starting row numerals and their respective finish row letters. Some of these spaces 16 are blank; however, others contain diverse commands or instructions that can either help or hinder each individual player, as will become apparent hereinbelow.
FIG. 2 depicts, generally at 22, the sets of cards that are used in playing the game of the present invention. As shown, each set 22a, 22b, 22c . . . 22n comprises a plurality of individual cards containing one of the game title letters. Thus, set 22a contains a plurality of cards each having the letter "M;" set 22b contains cards each having the letter "I;" set 22c contains cards each having the letter "S" and so on, with set 22n comprising a plurality of cards each containing the letter "S." It is to be understood that each set containing the same letter may be consolidated. Thus, sets 22b and 22e may be combined into one stack of "S"s; the sets 22i and 22L may be combined into one stack of "E"s; and the sets 22i and 22k may be combined into one stack of "T"s. However, it is also contemplated that the sets may remain separate as shown or, alternatively, they may be placed in their corresponding positions on the finish row 14.
The object of the game is to be the first player to take sufficient cards from the diverse card sets 22a . . . 22n to be able to form a single word from the many words that can be formed from the game letters. For example, with the letters of the words "MISSING LETTERS", the following words represent some of the winning possibilities:
______________________________________ MISSING SING LETTER IS LETTERS IN MISS MINE LET REST LETS IT______________________________________
The game may be played with three standard dice 26 as shown in FIG. 3 and playing pieces 28 (FIG. 4) of any suitable material, shape, size and colors. A single playing piece 28 is provided for each player. The board 10, similarly, may be fabricated of any suitable material and may be folding or nonfolding, as is well known in the art.
METHOD OF PLAYING
Each player tosses the dice 26, with the player having the highest dice total moving his playing disc 28 to the starting row lane and space 18 which corresponds to the dice total. As shown in FIG. 3, with a dice total of ten, the player would place his piece 28 in space 18 having the numeral ten. This procedure is followed by all the players. If the dice total happens to be more than 16, then the player tosses again until the total is 16 or less. If a player lands on a space occupied by a previous player in the starting row 12, he must toss the dice again until he lands on an unoccupied space in row 12. After one round is completed and all the players are on separate numbered spaces 16 in starting row 12, they can then toss the dice again in an attempt to move up the lane toward the finish row letter that is aligned with their starting row number. Thus, a player in starting row ten will be moving up the lane towards the letter "L".
If a player successfully moves up the lane to the finish row 14 he may then take a letter from one of the card sets 22 that corresponds to the letter on the space 20 in the finish row. Thus, the player in lane 10 should be able to take the letter "L" from the card set 22L. A player may decline to take the letter in the finish row if he feels it will not help him towards the formation of his word. Further, in order to land on the finish row letter, the player need not have the exact dice total. For example, if the player is three spaces away from the finish row 14 and he throws a five, he can land on the finish row and take a letter. After reaching the finish row and taking or declining his letter the player then starts over on his next throw of the dice in starting row 12 and either moves up the same lane or a new lane towards the same or a new letter in the finish row. The first player to form a word from the letters in the finish row 14 wins the game.
As previously indicated, some of the spaces 16 between the starting row and the finish row are provided with commands, directions or instuctions for the players if they land on any one of these spaces. These commands or directions can be summarized as follows:
______________________________________1. SUPRISE Player can choose any letter and will win the game if the letter completes his word.2. RIGHT LANE Player must move one lane over to his immediate right, if unoccupied. If occupied, player must wait his next turn.3. LEFT LANE Player must move one lane over to his immediate left, if unoccupied. If occupied, player must wait his next turn.4. LOSE NEXT Player must skip his next turn. TURN5. MOVE 4 SPACES Player must move 4 spaces towards the finish row letter. If fourth space is occupied, player must wait his next turn.6. MOVE 1 SPACE Player must move one space forward if unoccupied.7. BACK 1 SPACE Player must move backward one space, if unoccupied.8. LOSE 4 TURNS Player must skip four consecutive turns.______________________________________
An example of one player's moves can be seen from the following simulation:
1. Dice total is 10--player moves to space number ten in starting row 12.
2. Dice total is 4--player moves four spaces up towards the letter "L", but he lands on "LOSE NEXT TURN." Player must then skip a turn.
3. Dice total is 9--player moves his piece 28 to finish row 14 and takes the letter "L" from card set 22L. Since player has not formed a word, he must start again in starting row 12.
4. Player's next dice total is 8--player moves to space number eight in starting row 12.
5. Player's dice total is 5--player lands on "LEFT LANE", he moves his piece into the space 16 immediately to the left in lane number seven in alignment with finish row letter "I".
6. Dice total is 7--player lands on finish row and takes the letter "I" from the card set 22e.
7. Next dice total is 18--player tosses the dice again.
8. Dice total is 16--player moves to space number sixteen in starting row 12 in alignment with finish row letter "S".
9. Dice total is 8--Player lands on "SURPRISE" where he has the option of choosing any letter he may want from the card sets 22. He would take the letter "L" to spell the word "ILL" and thereby win the game.
It can be thus seen that the present invention provides a very simple, quick and challenging game for two or more players. Variations in play are possible according to the age, skill and intelligence of the players. For example, one option would be to require a player to use all the letters he has to form a word before he can win the game. Another option would be to require a player to land on the finish row only with the exact dice total that will enable him to arrive there.
Although a preferred embodiment of the present invention has been disclosed and described, changes will obviously occur to those skilled in the art. It is, therefore, intended that the present invention is to be limited only by the scope of the appended claims.
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A word forming game apparatus including a game board, game cards, game pieces and a plurality of dice. The game board contains a plurality of spaces defining columns or lanes, the extreme edges of which are bounded by a starting row and a finish row, respectively. The starting row has a plurality of adjacent spaces that are consecutively numbered, whereas the finish row has a plurality of adjacent spaces in alignment with the numbered spaces of the starting row; each space of which containing a letter of the alphabet that corresponds to the title word(s) of the game.
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TECHNICAL FIELD
[0001] The present invention relates generally to the field of ASIC design and manufacturability, and in particular, to built-in self test mechanisms for memory.
BACKGROUND INFORMATION
[0002] Many integrated circuits facilitate defect identification using Built-In Self Test (BIST) mechanisms. The term “BIST” can refer to testing techniques in which parts of a circuit (chip, board, or system) are used to test the circuit itself. BIST circuits may be formed directly on the same chip when forming the integrated circuits and other circuit components that require testing. Such BIST schemes may be used during wafer level manufacturing test to screen out defects. Alternatively, BIST schemes may be used after each power-on to conduct self-checking of the circuits. The term “ABIST,” can mean “Array BIST,” or a BIST system designed to test an embedded memory device. Testing multi-port memory (e.g., Processor internal Register Memory Array) may present complications, such as how to fully test port interactions without necessitating large amounts of extra test-only hardware. Multi-port memory may be tested using a micro-architecture specific program such as an Architectural Verification Program (AVP). An AVP may be any software or firmware program that is intended to execute in a chip to verify architected functions of the chip. In the case of multi-port memories, an AVP may be designed to fully verify a particular embedded memory. However, if the memory is later embedded in a different chip or has a slightly different implementation, the AVP program must be changed. In addition, the AVP is generally developed late in the design process, typically after the hardware is developed, and it is a complex process to test memory array cell characteristics. Since creating and maintaining such AVP programs can be labor-intensive and burdensome, it is difficult to accomplish this late in the design process without causing schedule or quality slippage.
[0003] Implementing an ABIST system may require using valuable chip area to incorporate ABIST hardware. Accordingly, to optimize an ABIST scheme, it may be desirable to reduce the amount of “test-only” hardware needed by an ABIST system. Test-only hardware may be considered any hardware unnecessary for normal functionality but necessary for ABIST testing. Such test-only hardware occupies valuable space on a chip and should be minimized. Optimizing an ABIST system may also require testing at speeds that simulate functional conditions and exercise the dynamic characteristics of memory circuits. Additionally, scanned ABIST testing of consecutive reads, consecutive read/write, or consecutive writes of a memory typically requires additional logic configured as a set of shadow latches for addressing.
[0004] In summary, an invention is needed that allows scanned memory ABIST testing of multi-ported memory arrays at functional speeds, while minimizing the amount of test-only hardware needed for ABIST testing and reducing the potential for schedule slippage.
SUMMARY OF THE INVENTION
[0005] The present invention addresses the above issues by providing mechanisms for scanned memory testing that use functional data latches from one port as shadow latches for another port during ABIST testing to achieve functional speed testing of multi-ported memories.
[0006] An embodiment of the present invention is a memory array including a first and second port. The memory array includes a first functional latch bank. During normal (non-test) operation of the memory array, the first functional latch bank holds a first memory array address. The memory array includes a second functional latch bank. During the normal operation of the memory array, the second functional latch bank holds a second memory array address. During a test operation, a first plurality of latches from the first functional latch bank are interleaved to act as a plurality of shadow latches for a second plurality of latches from the second functional latch bank. An embodiment of the present invention includes a controller and an additional test-only shadow latch coupled to the controller and to a first latch of the first bank of functional latches.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] For a more complete understanding of the present invention and its advantages, refer to the following description taken in conjunction with the accompanying drawings, in which:
[0008] FIG. 1A illustrates a portion of a central processing unit (CPU) that incorporates scanned memory testing in accordance with an embodiment of the present invention;
[0009] FIG. 1B illustrates an ABIST controller operatively coupled to a multiport memory array;
[0010] FIG. 2A illustrates a hardware environment for testing a single-port RAM using a shadow latch bank of test-only latches;
[0011] FIG. 2B illustrates a hardware environment for testing a multi-port RAM using a shadow latch bank of test-only latches;
[0012] FIG. 3A illustrates a hardware environment for testing a multi-port RAM using functional latches from port B as shadow latches for port A; and
[0013] FIG. 3B illustrates a hardware environment for testing a multi-port RAM using functional latches from port B as shadow latches for port A with additional circuitry for modifying the signals between the shadow latches and functional latches.
DETAILED DESCRIPTION
[0014] In the following description, numerous specific details are set forth such as specific data bit lengths, address lengths, widths of data lines, and array sizes, etc. to provide a thorough understanding of the present invention. However, it will be obvious to those skilled in the art that the present invention may be practiced without such specific details. In other instances, well-known circuits have been shown in block diagram form in order not to obscure the present invention in unnecessary detail. Some details concerning timing considerations, detection logic, specific ABIST software code and the like have been omitted inasmuch as such details are not necessary to obtain a complete understanding of the present invention and are within the skills of persons of ordinary skill in the relevant art. Refer now to the drawings wherein depicted elements are not necessarily shown to scale and like or similar elements may be designated by the same reference numeral through the several views.
[0015] FIG. 1A illustrates major components of CPU 101 , which may be part of a data processing system containing multiple CPUs. The components shown of CPU 101 are packaged on a single semiconductor chip. CPU 101 may conduct multiple instruction issuing and hardware multithreading by concurrently executing multiple instructions and multiple threads. To support multiple instructions executions and hardware multithreading, processor internal memory arrays such as floating point register 216 may have multiple ports with multiple read ports and one write port for each instruction issue pipe per each thread. Accordingly, in an embodiment of the present invention, floating point register 216 is a multi-port memory array that is subject to ABIST scanned testing.
[0016] Regarding the other components in FIG. 1A , CPU 101 includes instruction unit portion 200 , execution unit portions 210 and 212 , and storage control portion 220 . Instruction unit 200 obtains instructions from L1 I-cache 106 , decodes instructions to determine operations to perform, and resolves branch conditions to control program flow. Execution unit 210 performs arithmetic and logical operations on data in registers, and loads or stores data. Storage control unit 220 accesses data in the L1 data cache 221 or interfaces with memory external to the CPU where instructions or data may be fetched or stored.
[0017] Instruction unit 200 comprises branch unit 202 , buffers 203 , 204 , 205 , and decode/dispatch unit 206 . Instructions from L1 I-cache 106 are loaded into one of the three buffers from L1 I-cache instruction bus 232 . Sequential buffer 203 may store 16 instructions in the current execution sequence. Branch buffer 205 may store 8 instructions from a branch destination. These are speculatively loaded into buffer 205 before branch evaluation, in the event the branch is taken. Thread switch buffer 204 stores 8 instructions for the inactive thread. In the event a thread switch is required from the currently active to the inactive thread, these instructions will be immediately available. Decode/dispatch unit 206 receives the current instruction to be executed from one of the buffers, and decodes the instruction to determine the operation(s) to be performed or branch conditions. Branch unit 202 controls the program flow by evaluating branch conditions and refills buffers from L1 I-cache 106 by sending an effective address of a desired instruction on L1 I-cache address bus 231 .
[0018] Execution unit 210 comprises S-pipe 213 , M-pipe 214 , R-pipe 215 , and a bank of general purpose registers 217 . Registers 217 are divided into two sets, one for each thread. R-pipe 215 is a pipelined arithmetic unit for performing a subset of integer arithmetic and logic functions for simple integers. M-pipe 214 is a pipelined arithmetic unit for performing a more complex larger set of arithmetic and logic functions. S-pipe 213 is a pipelined unit for performing load and store operations. Floating point unit 212 and associated floating point registers 216 are used for certain complex floating point operations that typically require multiple cycles. Similar to general purpose registers 217 , floating point registers 216 are divided into two sets, one for each thread.
[0019] Storage control unit 220 comprises memory management unit 222 , L2 cache directory 223 , L2 cache interface 224 , L1 data cache (D-cache) 221 , and memory bus interface 225 . L1 D-cache 221 is an on-chip cache used for data (as opposed to instructions). L2 cache directory 223 is a directory of the contents of CPU 101 's L2 cache (not shown). L2 cache interface 224 handles the transfer of data directly to and from L2 cache (not shown). Memory bus interface 225 handles the transfer of data across a memory bus (not shown), which may be to main memory (not shown) or to L2 cache units (not shown) associated with other CPUs (not shown). Memory management unit 222 is responsible for routing data accesses to the various units. For example, when S-pipe 213 processes a load command, requiring data to be loaded to a register, memory management unit may fetch the data from L1 D-cache 221 , L2 cache (not shown), or main memory (not shown). Memory management unit 222 determines where to obtain the data and instructions. L1 D-cache 221 is directly accessible, as is the L2 cache directory 223 , enabling memory management unit 222 to determine whether the data is in either L1 D-cache 221 or the L2 cache (not shown). If the data is in neither on-chip L1 D-cache nor the L2 cache (not shown), it is fetched from memory bus (not shown) using memory interface 225 . Similarly, if the instruction is not in L1 I-cache 106 , it is fetched from the L2 cache (not shown) or the main memory through path 233 .
[0020] Although FIG. 1A illustrates an embodiment of the present invention implemented within a CPU, the present invention is not limited to such embodiments. The present invention can also be embodied in other devices having logic circuitry and memory embedded on the same semiconductor chip, such as in an I/O (input/output) adapter in a data processing system. Additionally, embodiments of the present invention may be implemented in conjunction with other multiport arrays, such as general purpose registers 217 ( FIG. 1A ).
[0021] FIG. 1B illustrates the interconnection of an ABIST controller 170 with floating point registers 216 , in accordance with an embodiment of the present invention. As shown, ABIST controller 170 is configured to test floating point registers 216 from FIG. 1A . ABIST controller 170 receives an ON signal 172 from an external source (not shown). In response, ABIST controller 170 turns ON and sends test data over test data line 168 to floating point registers 216 . The controller 170 may receive the test data on line 176 from an external pattern generator or internal pattern generator (not shown) within 170 may be capable of generating common test patterns. The test data may be any of several common test patterns including a solid ‘1’, solid ‘0’, checkerboard, row stripe, or column stripe. ABIST controller 170 receives response data from floating point registers 216 over line 166 . The test data out from line 166 can be processed by a data comparator (not shown) in the ABIST controller 170 to compare data received on line 166 with expected data values. The controller 170 may use information from the comparator in ABIST controller 170 to determine whether the floating point registers 216 pass or fail ABIST testing. Test results may be sent from the ABIST controller 170 to an external source (not shown) over test results line 174 .
[0022] When testing memory such as floating point registers 216 , it may be advantageous if ABIST controller 170 performs serial scanning of data rather than scanning the data in parallel, as in a typical ABIST scheme. Serially scanning the data using scanned ABIST testing may be advantageous because scanned ABIST testing generally requires fewer resources such as wiring, logic space, and the like. Accordingly, it may be easier to add new arrays to a system if ABIST testing is done serially rather than in parallel, because adding new arrays would require fewer additional wiring and other resources.
[0023] Referring now to FIG. 2A , circuitry 250 is illustrated. Circuitry 250 contains a single port RAM 252 . Read and write addresses are shared and fed through RAM-address 257 . FIG. 2A depicts using address/data latch bank 256 and shadow latch bank 254 for performing memory testing of RAM 252 . RAM 252 could correspond to a single-ported version of floating point registers 216 ( FIG. 1A ), or any other single-port RAM. In operation, latch bank 256 stabilizes and holds functional addresses for sufficient time to meet timing requirements for the addresses presented to inputs of RAM 252 . Test data and addresses may be sent from ABIST controller 170 over line 168 to functional hold latches in latch bank 256 . Output data is sent back to ABIST controller through line 166 .
[0024] As shown in FIG. 2A , RAM 252 is a single port RAM that may be tested using scanned ABIST controlled by ABIST controller 170 . For functional mode, RAM-address 257 and RAM-data in 258 are fed to the latch bank 256 for writing into RAM 252 . Alternatively, RAM-address 257 is fed to latch bank 256 for reading RAM 252 . For functional reads, RAM output is captured by the output latch bank 253 . For scanned ABIST, shadow latch bank 254 is required. Shadow latch bank 254 is made up of test-only shadow latches. Shadow latch bank 254 allows the test environment to test the device under more stressful conditions, such as performing a READ operation followed by another READ operation to two different addresses upon successive applications of a functional clock (not shown) running at functional clock speeds. As shown in FIG. 2A , circuitry 250 requires one additional shadow latch for each functional hold latch. The shadow latches in shadow latch bank 254 represent additional test-only overhead, because they are not used for functional purposes during operation.
[0025] FIG. 2B illustrates a hardware environment 260 for carrying out ABIST testing using test-only hardware latches in latch bank 264 as shadow latches to the functional latches in latch banks 261 and 262 . RAM 265 depicts a multiport RAM containing port A and port B. For simplicity and clarity, components such as data ports are omitted from RAM 265 as shown, since such ports are typically understood by those of ordinary skill in the art.
[0026] For testing port A, ABIST controller 170 sends test address data over line 168 for shadow latch bank 264 , hold latch bank 261 , hold latch bank 262 , port A, and port B. In functional mode, RAM-address A 266 and RAM-address B 267 are latched by latch banks 261 and 262 , and the output latch bank 268 and output latch bank 269 capture RAM 265 outputs. In testing, the outputs of RAM 265 are sent to the ABIST controller 170 through scan data path 166 for testing and verifying. Latch bank 264 represents the type of overhead intended to be reduced by principles of the present invention.
[0027] FIG. 3A illustrates representative circuitry 312 for performing ABIST testing of multi-port memory 314 in accordance with an embodiment of the present invention. Memory 314 could correspond to floating point registers 216 from FIG. 1A . As shown, memory 314 comprises two ports; however, showing only two ports in memory 314 is not meant to limit the scope of the present invention, and principles of the invention can be extended to registers, RAM, or other memory with three or more ports. In reality, floating point (FP) registers may be implemented with six-reads/three-writes ports or more to accommodate multi-issues and multi-threads. In operation, functional latch bank 320 holds RAM-address A 340 for port A. Similarly, in operation, functional latch bank 322 holds RAM-address B 350 for port B. Accordingly, functional latch banks 322 and 320 hold addresses to meet the timing requirements of memory 314 . However, during ABIST testing, latches in functional latch bank 322 are interleaved to act as shadow latches for latch bank 320 . Using functional hold latches in latch bank 322 as shadow latches serves to limit the amount of test-only hardware needed for ABIST testing.
[0028] During ABIST testing of port A ( FIG. 3A ), ABIST controller 370 sends test data to functional latch bank 320 . Latch 324 acts as a shadow latch for latch 326 . Likewise, latch 328 acts as a shadow latch for latch 330 . As shown in FIG. 3A , latch 324 is the only test-only latch needed for testing of port A. Therefore, using the ABIST scheme shown in FIG. 3A reduces the amount of test only hardware needed when compared to the ABIST scheme shown in FIG. 2B . Using port B's functional latch bank 322 during testing of port A reduces the need to have dedicated shadow latches such as those in shadow latch bank 264 ( FIG. 2B ). Instead of having a whole bank of shadow latches such as shadow latch bank 254 or 264 ( FIGS. 2A and 2B ), circuitry 312 utilizes shadow latch 324 . During testing, shadow latch 324 may provide predecessor values to the functional hold latch 326 during read/write operations that occur on successive clock cycles. Such testing using back-to-back read and/or write cycles may stress a memory device and expose defects that otherwise would go undetected. Therefore, shadow latch 324 provides the ability to test RAM 314 on successive clock cycles, which is advantageous in detecting certain defects that may exist in RAM 314 . In addition to shadow latch 324 , embodiments of the present invention may utilize other latches (not shown). For example, a latch in the scan path between different types of memory ports, such as between the address and data ports or between the data and controls.
[0029] FIG. 3A illustrates a scheme for interleaving functional latch banks from one port to provide shadow latches for another port during testing. In an embodiment of the present invention, the principles shown in FIG. 3A can be extended to RAMs with more than two ports. For an odd number of ports, a similar ABIST scheme can interleave three ports as necessary. This type of approach supports a common scannable ABIST engine (such as ABIST controller 370 ) that runs at functional speeds. Running at functional speeds can be helpful in observing transition defects that might not be detected running at lower speeds. In addition, by not requiring dedicated shadow latches for ABIST testing, embodiments of the present invention require less logic, overhead, and labor to accomplish ABIST testing. This results in designs that use less chip area and power. Consequently, these designs may run faster and cooler than other scannable ABIST solutions.
[0030] FIG. 3B illustrates a hardware environment implementing principles of the present invention. Like-numbered elements in FIG. 3A and FIG. 3B correspond and descriptions for like-numbered items are not repeated. Compared to FIG. 3A , FIG. 3B adds circuit elements shown in circuit bank 402 . During ABIST testing, circuit bank 402 functions to alter the signals between shadow latch bank 322 and functional latch bank 320 . In an embodiment of the present invention, circuit bank 402 is comprised of an ABIST controllable function such as an inverting function; however, the components of circuit bank 402 may also be higher function logic such as linear feedback shift registers (LFSRs) that could automatically allow higher-level operations such as increasing or decreasing sequences of numbers to latch bank 320 .
[0031] Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions, and alterations could be made herein without departing from the spirit and scope of the invention as defined by the appended claims.
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A system for at-functional-clock-speed continuous scan array built-in self testing (ABIST) of multiport memory is disclosed. During ABIST testing, functional addressing latches from a first port are used as shadow latches for a second port's addressing latches. The arrangement reduces the amount of test-only hardware on a chip and reduces the need to write complex testing software. Higher level functions may be inserted between the shadow latches and the addressing latches to automatically provide functions such as inversions.
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BACKGROUND OF THE INVENTION
This invention relates to an illuminator suited for radiology use, and is especially directed to a illuminators and light boxes for viewing radiographs (x-rays) or for viewing photographic negatives or transparencies. The invention is more specifically concerned with an x-ray illuminator that provides even lighting over its surface without bright or dark areas to facilitate film-based studies by radiologists or other professionals.
At present, where the radiologist is working with traditional film images a lighted illuminator is required, which typically is a light box having lamps contained inside it and a flat glass diffuser or screen on the front face for back lighting the radiographs. Illuminators are frequently used in hospitals and clinics for analysis and study of a patient's internal tissues.
Where soft tissues are involved, an extremely even lighting is required. However, in a traditional back-lighted unit there is considerable variance in light intensity over the area of the diffuser screen, depending on the relative position of the bulb or tube behind it. Where soft tissues are the subject of the radiograph, even a small variation in illumination intensity can mask rather faint details in the images. For certain applications, these variations can obscure changes from one image to another, such as x-rays taken of the same patient at two different times.
The typical illuminator is generally in the form of a light box, containing a number of fluorescent tubes, and a glass plate on the front wall serving as diffuser screen. A reflector, usually in the form of a metal sheet coated with high-reflectance white paint, is positioned behind the tubes. There are also ballasts and other electrical drive elements inside the light box for providing the appropriate electric power to the tubes. Because the tubes are individual light emitters, the light emanating through the front diffuser screen tends to be more concentrated at the tube positions. Also, even the most carefully engineered fluorescent tubes tend to be measurably brighter at the center of the tube than near the ends, and so the illumination likewise varies from bright to dim between screen positions over the center and ends of the tubes.
The current international standards for x-ray illuminators, which have been proposed for the United States, include the need for uniformity of light output across the entire viewing surface of the front diffuser screen. There are also certain minimum light output standards established in this country for mammography illuminators. The illuminator industry has faced a problem in attaining these two goals with existing fluorescent tubes, as these tubes exhibit a high degree of non-uniformity over the length of the lamp. For instance, a standard 4-foot-long or 5-four-long fluorescent tube may have a center portion that is 50% brighter or more than the regions near the two ends of the same tube. However, uniformity of light output is necessary in comparing radiograph findings within regions of the same radiograph image, and also when comparing current film records with older sequential studies. Even, uniform light output across the illuminator aids in delineation of significant findings which could potentially be masked by non-uniformities in the illumination.
The industry is aware of this problem, and there have been several attempts made at correcting non-uniformity of light distribution.
One prior attempt has involved using an array of smaller, i.e., 18-inch, bulbs or tubes aligned vertically, rather than having a smaller number of long tubes arranged horizontally. These usually require the array to be linear, although a hatched or herringbone pattern is possible. Neon bulbs can be included at certain places in the grid to try to improve uniformity. However, it has been found that the light output from the array of smaller tubes cannot match the light output that can be attained by using the larger tubes. Other factors also disturb the attempts to obtain uniformity. There can be light output variation of 10% or more between fluorescent tubes, even when coming from the same manufacturing batch. There can also be variances from ballasts, even if the ballasts are considered “matching,” and from paint variations in different reflector sections. In addition, the shorter fluorescent tubes have been found to have reduced lamp life as compared with longer tubes.
Prior attempts have been made to improve the reflector to better distribute the light around both ends of the tubes, that is, to try to direct more light into these “dead” areas. These reflectors can be designed in a parabolic curve or a shape simulating a parabolic curve over the lengthwise direction, with the bulb centered longitudinally across it, in an attempt to distribute more light into the area between bulbs. Additional angled reflectors may be used, usually with only limited success, in an attempt to bolster light output at the tube-end portions of the illuminator, i.e., at the “dead” areas.
Other attempt have included increasing the box depth to increase light diffusion. Again this has had only limited success, and the larger box size also creates additional inconvenience.
OBJECTS AND SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an x-ray illuminator that avoids the drawbacks of the prior art.
It is another object to provide an illuminator that compensates for any unevenness in illumination due to the lamps and reflectors, to permit more reliable analysis of radiographic images.
It is a further object to provide an illuminator that attains even illumination without the need for additional lamps or additional reflectors.
In accordance with an aspect of the present invention, an x-ray illuminator comprises a housing having a front side; a plurality of fluorescent tubes or the equivalent within the housing; an internal reflector situated behind the fluorescent tubes for directing light from the tubes towards the front side of the housing; a transparent diffuser plate at the front side of the housing on which radiographs or transparencies are placed for viewing; and circuitry for driving the fluorescent tubes. To obtain uniform illumination the reflectance of the reflector can be varied over its surface, the transmissivity of the screen can be varied over its extent, or both. For example, the internal reflector can have a reflectance that is reduced at positions directly behind centers of the fluorescent tubes and which gradually increases to maximum reflectance at positions at ends of the tubes and at positions away from centerlines of the tubes. Alternatively, the diffuser plate has a transmissivity that is reduced at a position directly in front of the centers of said fluorescent tubes and gradually increases to a maximum transmissivity at positions towards the ends of. the tubes and at positions away from the centerlines of the tubes.
Correction of non-uniformity of light output can be carried out by using the following procedure: a. Surveying the light output of the viewing surface at multiple points; b. From the survey, creating a “topographical” map of light output for the entire viewing surface, with contour lines of equal luminance being displayed; and c. From this topographical map of light output, designing a reflector or absorber which is painted with a gradient of increasingly absorptive paint at regions of increased light output. This generally means there is a higher concentration of photo-absorbent of dark pigments in the center, and progressively lower concentrations of dark pigments towards the ends of the fluorescent tubes and other reduced-output regions. This is generally the opposite of what is currently done, where the reflector is coated throughout with as reflective a medium as possible. In contrast to the prior art, the technique of this invention intentionally reduces light output in the brightest areas of the illuminator to equal that of the areas of lowest illumination.
The result of this process is a reflector and/or absorber designed to be highly reflective in the regions of decreased light output so as to augment light output in these areas, but to be less reflective in the regions of the center portion of the bulb to reduce the light output in the bright regions. Using this technique, uniformity is achieved using presently existing non-uniform lamp tubes, and without having to include additional reflectors or other hardware.
Recently, there has arisen a need for increased light output for X-ray illuminators, for example, for interpreting the fine changes on dense images, such as mammographs. At the same time, it is desired to reduce the need for supplemental X-ray studies and to minimize the patients' exposure to X-rays. The standard 18-inch lamps and magnetic ballast combinations can barely meet the current FDA requirement for light output for mammography illuminators. For that reason, fluorescent tubes of much higher output are required. The larger tubes can meet the high illumination requirements, but their non-uniformity is much more pronounced. However, the excellent light output obtainable with these tubes makes it possible to take the approach of the present invention, whereby light output can be deliberately decreased in some areas to achieve uniformity.
In this invention, a specialized reflector/absorber system can be used that is designed to reduce light output in the center, where light output is at its maximum, but gradually increase in reflectance towards the tube ends and also towards positions away from the axes of the tubes. The reflector/absorber can be designed based on the topographical map obtained in a survey of the output (using a standard reflector and diffuser screen). Then a less reflective paint, i.e., paint achieving a gradient of reflectivity, is applied on the reflector to make the output more uniform, so the reflector is more reflective at the ends, and less reflective at the center.
The above and many other objects, features, and advantages of this invention will become apparent from the ensuing description of a selected preferred embodiment, which is to be considered in connection with the accompanying Drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a topographic map of light intensity for a fluorescent tube over a portion of an illuminator viewing surface.
FIG. 2 is a map of reflector or absorber gradient design based on the topographic map of
FIG. 3 is a sectional side view of a radiographic illuminator of an embodiment of this invention.
FIG. 4 is a sectional side view of an illuminator according to an alternative construction.
FIG. 5 is a front plan view of the illuminator with diffuser screen removed showing the reflector adapted according to an embodiment of this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to the Drawing, FIG. 1 illustrates a topographical map of the illumination output intensity for an illuminator, here for the sake of simplicity, showing the output for a single fluorescent tube 10 (illustrated in ghost lines). This is obtained by taking a survey over the entire height and width of the front illuminator diffuser screen, and then plotting the shapes of contour lines of equal intensity. Here, for sake of simplicity, there are three contour lines shown, dividing the area into a central zone 11 of maximum intensity, and surrounding zones 12 , 13 , of gradually reduced intensity, and finally an outer zone 14 of lowest intensity. The zone 11 of highest intensity is somewhat oval in shape and centered on the tube axis over the mid-portion of the tube 10 . The intensity is lowest at the ends of the tube 10 and at the areas farthest from the axis of the tube, i.e., in zone 14 . In a practical embodiment, there could be many more contour lines, and a more gradual delineation of the light output intensity.
Once the topographical map of FIG. 1 has been created, then a corresponding absorption pattern 15 can be created, as shown in FIG. 2 . This pattern 15 constitutes a gradient design based on the light output intensity pattern, and has a zone of maximum absorption 16 that corresponds to the center of the lamp tube 10 , and then successive surrounding zones 17 and 18 of lesser absorption, and an area of minimal absorption 19 , that is, maximum reflectance in the case of a reflector. Again, in a practical embodiment, there could be more than the number of zones shown here, and the absorptive material on the reflector would have a more continuous gradient from the center outwards. However, FIGS. 1 and 2 are shown with only the four zones here to simplify the discussion. It is possible for a reflector/absorber to have as few as two zones.
An illuminator 20 which can incorporate the improvements of this invention is shown in FIG. 3 . Here, the illuminator comprises a housing 21 with four fluorescent lamps or tubes 22 arranged parallel to each other. Here, the tubes 22 are of a high-luminance or high intensity design. There is a flat reflector 23 disposed behind the lamps 22 , with angled sides 23 a outside the first and fourth ones of the lamps 22 . This reflector 23 is coated with a reflective paint, with a high a reflectivity as possible, except for portions that are treated to compensate for light intensity variations, as discussed further. A front diffuser 24 is mounted in an open front of the housing 21 over the lamps 22 , and can be formed of a glass plate that is etched or frosted, or Plexiglas. Electrical drive equipment 25 (i.e., ballasts) for supplying the appropriate electrical power to the lamps is disposed within the housing, here shown behind one of the angled wall portions 23 a of the reflector.
FIG. 4 shows another illuminator 20 ′ according to an alternative embodiment. Here, elements of the illuminator that are identical with the illuminator 20 of FIG. 3 are identified with the same reference numbers and a discussion thereof will not be repeated. However, in this embodiment the reflector 23 ′ has a parabolic or somewhat parabolic profile, with parabolic shaped sections 23 a′ for each of the four lamps 22 . Shaped reflectors such as these may help to overcome some of the unevenness of illumination.
A top plan view of the illuminator 20 of FIG. 3 is shown in FIG. 4, with the front diffuser plate and the fluorescent tubes having been removed to exhibit the reflectivity (or absorption) pattern on the reflector 23 . Sockets 26 for the fluorescent tubes 22 are illustrated here, and define the positions of the tubes 22 when they are in place. Here, the reflector is generally coated with a highly reflective white, but a pattern 27 of an absorptive medium is shown, with generally oval portions 28 centered on the position of each lamp. Each portion of the pattern is concentrated at a location corresponding to the center and axis of each lamp, and becoming gradually less absorptive towards the two ends of each lamp, i.e., towards the lamp sockets 26 , and also becoming more reflective, or less absorptive, at positions between the positions of the tubes 22 .
While not shown here, the illuminator can also include an x-ray holder, which is disposed along an upper or top side of the illuminator 20 , for holding the radiographs against the screen 24 . Also, means can be provided on the back side of the housing 21 for attaching or hanging the illuminator on a wall.
The reflectors for all the illuminators of a single design can be painted with the same pattern. It is recommended that when the fluorescent lamps are installed, both initially and later to replace a failed tube, that all four tubes 22 be replaced at the same time, with tubes from the same batch or lot. These can be pre-tested to obtain a set of lamps of more-or-less matched intensity.
Also, while the invention has been described in terms of a fluorescent tube illuminator, the invention should not be limited to that but could be used with other types of lamps being the source of illumination. In each case a survey of the pattern of illumination intensity would be used to create a compensating pattern of reflectivity behind the lamps.
While the invention has been described hereinabove with reference to a preferred embodiment, it should be recognized that the invention is not limited to that precise embodiment. Rather, many modification and variations would present themselves to persons skilled in the art without departing from the scope and spirit of this invention, as defined in the appended claims.
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An x-ray illuminator achieves uniform illumination intensity across the front glass diffuser screen. The reflectance of the reflector is varied over its surface, the transmissivity of the screen can be varied over its extent, or both. The internal reflector can have a reflectance that is reduced at positions directly behind centers of the fluorescent tubes and which gradually increases to maximum reflectance at positions at ends of the tubes and at positions away from centerlines of the tubes.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 15/075,870, filed Mar. 21, 2016, which is a continuation of U.S. application Ser. No. 13/997,395, filed Sep. 16, 2013, which claims the priority of PCT/EP2011/073533, filed on Dec. 21, 2011, which claims priority to German Application No. 10 2010 063 998.2, filed Dec. 22, 2010 and German Application No. 10 2011 005 154.6, filed Mar. 4, 2011, the entire contents of each of which are hereby incorporated in total by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a combined light modulator device for a holographic or an autostereoscopic display with observer tracking. In the context of the present invention, a combined light modulator device is understood to be a device which changes in a multi-stage process the properties and/or the direction of light which is emitted by one or multiple real or virtual light sources.
[0003] Here, a virtual light source is a light source which is only seemingly situated at a certain position, i.e. a light source which appears to be there as a result of manipulating light of a real light source by—typically static—imaging means, such as, for example, a mirror and/or beam confining means such as apertures.
[0004] In the context of this patent application, a holographic display is a display device for three-dimensional image data where the three-dimensional object data of the scene to be represented are encoded in the form of diffraction patterns of the scene to be reconstructed. The reconstruction of a three-dimensional scene in a large visibility region at high quality requires both great computing power and a high-resolution light modulator.
[0005] In document DE 103 53 439 B4, the entire contents of which being fully incorporated herein by reference, the applicant has thus proposed a method in which the wave front is only computed for a small visibility region whose diameter is only little larger than the diameter of an eye pupil of an observer eye. Consequently, each of the object points to be reconstructed only needs to be encoded in a small region of the light modulator in particular sub-holograms.
[0006] For this, sufficiently coherent light, which is emitted by at least one light source, illuminates at least one light modulator and is imaged to at least one observer eye by a field lens. The reconstruction of the three-dimensional scene for the other observer eye can be generated by alternately switching on at least one other light source in synchronism with the light modulator while writing a corresponding hologram or corresponding sub-holograms to the light modulator. Here, colour representation is possible by way of spatial or temporal interleaving (space or time division multiplexing) of the hologram information for each colour component. To enable the observer to move freely in front of the display, the focal regions are tracked to the observer eyes by switching on further light sources separately. For this, the coordinates of the eyes of one or multiple observers are continuously determined with the help of a position detection system.
[0007] Here, the reconstruction of the scene can be adapted to the new observer position by recalculating of the diffraction pattern. It is also possible to provide reconstructions for multiple observers by way of temporal interleaving (time division multiplexing).
[0008] To provide observer tracking along the optical path, the focal plane of the focusing unit, and thus the size of the visibility region, is preferably additionally adapted to the eye positions of the observers.
[0009] In an autostereoscopic display (ASD) with observer tracking, it is not diffraction patterns that are encoded on the light modulator, but rather are the scene views for the particular eye written directly.
[0010] Observer tracking can be realised by way of direct or indirect displacement of the light sources. A known example of indirect displacement are deflection mirrors.
[0011] Numerous other methods of observer tracking are known. Observer tracking can be achieved, for example, by modifying the optical path in front of or behind the light modulator which is used for hologram encoding or for stereo representation. In addition to mechanical methods, methods of changing reflective, diffractive or refractive properties using adaptive optical systems are known.
[0012] Further, it is known to use combined tracking methods, i.e. methods which take advantage of a light-deflecting function that is static but varies across the surface area of the light-deflecting means.
[0013] In the patent application DE 10 2008 054 438 A 1 filed by the applicant, a matrix of electrically controllable fluid cells is proposed for observer tracking with the fluid cells having additional static light-deflecting means which, however, vary across the surface area of the matrix in order to realise or at least to support the function of a field lens. These light-deflecting means can, for example, comprise refractive elements, such as prisms or lenses, or diffractive elements, such as volume gratings or blazed gratings, i.e. gratings which are optimised for a certain wavelength.
[0014] The patent application DE 10 2009 028 626 A 1 filed by the applicant, the entire contents of which being fully incorporated herein by reference, teaches to use controllable diffractive gratings for observer tracking.
[0015] Here, multiple gratings of this kind with the same direction of deflection can also be arranged one after another in order to realise a larger deflection angle. Here, it is also possible to arrange at least two controllable deflection gratings one after another which are turned to one another by a fixed angle in order to achieve a two-dimensional deflection. By varying the written grating period, the diffractive gratings can realise a locally different deflection across the surface area of the deflection unit in order to realise or at least to support the function of a field lens.
[0016] In a controllable deflection grating whose grating period is variable so to set a desired diffraction angle, there is a minimum settable period due to the spatial resolution with which the deflection grating can be controlled. If the period is set, for example, using a grid-like electrode structure, there are limitations to the width and distance of the electrodes caused by the manufacturing process. In addition, electric stray fields or diffusing or diffractive components of the deflection grating, for example, cause cross-talking among set neighbouring phase values. They can also reduce the diffraction efficiency and thus cause the occurrence disturbing diffused light or light in higher diffraction orders.
[0017] Since in a grid-shaped diffractive structure the diffraction angle is inversely proportional to the periodicity of the diffractive structure, the available angular range and thus the tracking range of a single diffraction device is limited by the producible electrode pitch.
[0018] However, to be able to watch a 30 scene comfortably at various viewing angles, a display is required to have a large tracking range at a variable observer distance. A solution is thus sought which, the limited diffraction angle of a deflection element notwithstanding, provides a tracking range which is larger than that achievable with such element.
SUMMARY OF THE INVENTION
[0019] This object is solved according to this invention by the features of claim 1 .
[0020] A light modulator device for a holographic or an autostereoscopic display for the representation of three-dimensional image information with at least one real or virtual light source, at least one light modulator to which is written encoded image information of the image to be represented to at least one observer eye of at least one observer, a first and a second light-affecting means for changing the optical path of the light which is emitted by the light source, an eye position detection system for finding and following at least one eye position of the at least one observer of the image information and a system controller for tracking at least one visibility region of the image information based on the eye position information provided by the eye position detection system using the first and second light-affecting means is characterised by a first light-affecting means, which tracks the visibility region to the eyes of the observer in large steps within the observer range, and by a second light-affecting means, which tracks the visibility region to the eyes of the observer finely graduated or continuously at least within one such large step of the first light-affecting means with the help of at least one electrically controllable diffraction grating.
[0021] Here, the system controller chooses that direction of deflection of the first light-affecting means which comes closest to the currently selected eye position of the selected observer and sets it in the first light-affecting means. The differential angle between this deflection angle and the actually selected eye position is simultaneously or promptly computed by the system controller and set in the second light-affecting means.
[0022] Both eyes of a selected observer can be served by the system controller by way of time division multiplexing, where the eye position detection system provides the eye position information needed for this.
[0023] For a 3D representation, the image content to be represented, i.e. the particular stereo view or the encoded hologram, is adapted to the respective right or left eye by the system controller for this. The eye position detection system can also be designed such that it additionally serves as a system for detecting the viewing angle so to be able to reconstruct, for example, only those parts of a scene which the observer actually looks at in a system with a large total viewing angle.
[0024] Multiple observers can also be served by way of time division multiplexing, which requires fast light modulators and fast light-affecting means though.
[0025] Here, a refresh rate of at least 60 frames per second is required for each view in the time division multiplex mode to provide a non-flickering representation. If both the three colour components and the two eyes of each observer are served by way of time division multiplexing, this refresh rate relates to each view of one colour channel for one eye of one observer.
[0026] In particular in a projection system it is possible to use a separate deflection system for each observer eye, which allows simultaneous representation of image contents for both observer eyes through a beam combining system.
[0027] It is possible by adapting the image content to be represented to the actual observer position through the system controller that the observer seemingly moves around the image contents to be represented when he moves his head within the visibility region of the display, where this effect can also be exaggerated or reduced artificially.
[0028] Since it is very complicated to make achromatic diffractive beam deflecting elements, a colour representation is also realised by way of time division multiplexing of the individual colour components in a preferred embodiment.
[0029] Depending on the actual physical form of the light modulator device, the second light-affecting means with the controllable light-deflecting gratings can be disposed in front of or behind the first light-affecting means for rough light deflection. A light-affecting means for rough light deflection, which requires fixed angles of incidence to ensure proper function, such as, for example, volume gratings for diffractive beam deflection, is preferably arranged in front of the second light-affecting means.
[0030] One or both of the light-affecting means can be disposed in front of or behind the light modulator.
[0031] They can be designed to be used in conjunction with a transmissive, emissive or reflective light modulator.
[0032] A transmissive or reflective light modulator is used in conjunction with an illumination device, where the latter typically emits collimated light with which the light modulator is illuminated.
[0033] Examples of transmissive light modulators are liquid crystal modulators on a transparent substrate with a multitude of controllable liquid crystal cells which are arranged in rows and columns or modulators which are based on electrowetting cells.
[0034] Suitable reflective modulators include, for example, liquid crystal modulators on a reflective substrate (e.g. LCoS—liquid crystal on silicon) or micro-mirror arrays (e.g. DMD—digital micro-mirror device) as fast light modulators.
[0035] With a transmissive or reflective light modulator, the first and/or the second light-affecting means or parts thereof can be integrated into the illumination device.
[0036] If the light modulator is, for example, a phase-modulating light modulator where complex hologram values are encoded in two (two-phase encoding) or more phase pixels of the light modulator and where the associated phase values are thereafter combined by a beam combiner to form an intensity value with defined amplitude and phase value, then both light-affecting means are preferably arranged behind the light modulator if the beam combiner requires a defined direction of passage of the pencils of light.
[0037] Such a beam combiner is proposed, for example, in the hitherto unpublished German patent application DE 10 2009 044 910.8, the entire contents of which being fully incorporated herein by reference.
[0038] In an autostereoscopic display with a largely direction-independent amplitude-modulating light modulator or in a holographic display with a largely direction-independent complex-valued light modulator, it can be preferred, however, to integrate one or both light-affecting means wholly or partly into the illumination device of the light modulator.
[0039] Remaining direction-specific intensity dependencies can preferably be allowed for by the system controller when encoding the image information, so that these dependencies can be compensated.
[0040] Emissive light modulators, such as electroluminescence displays or plasma displays do not require an illumination device, because they actively serve as a light source themselves. Since their individual pixels are mutually incoherent, they are preferably used as light modulators in autostereoscopic displays.
[0041] In holographic displays, they may be used as a switchable light source combined with a collimation unit of the illumination device of a transmissive display, if the size of a pixel is small enough to exhibit a sufficient coherence length.
[0042] The two light-affecting means are controlled by the system controller such to direct the beams which are emitted by the light sources such that the currently represented information for a particular observer eye lies in the viewing range of that eye.
[0043] Here, depending on the physical form and type of encoding, the optical path may be affected in the horizontal direction only or both in the horizontal and vertical direction.
[0044] Tracking the visibility region in the horizontal direction only greatly contributes to the simplicity of the arrangement, because light-affecting means which can only change the optical path in one direction suffice.
[0045] In a holographic display, the computing power needed for hologram computing is substantially reduced when using one-dimensional encoding methods compared with two-dimensional encoding methods.
[0046] In one-dimensional observer tracking, it is possible to use real or virtual line light sources. They can, for example, be columns of an emissive display combined with an upstream collimation unit in the form of cylindrical lens arrays. In autostereoscopic displays, it is common to realise horizontal observer tracking only.
[0047] By changing the position of a real or virtual light source in front of a collimation unit in the horizontal or vertical direction, the direction of the collimated illuminating pencil of light can be changed in the horizontal or vertical direction. This can be done, for example, by switching on or controlling the brightness of individual light points or light point clusters of a high-resolution matrix of light sources in conjunction with an upstream array of collimation elements, for example a lens array.
[0048] For one-dimensional deflection, it is possible to use illuminating stripes in conjunction with an array of cylindrical lenses.
[0049] A deflection of the light points or light stripes can also be realised by mechanical or scanning methods.
[0050] The size of the light spot in the observer plane can be adjusted by shifting the light sources in the direction of the optical axis of the corresponding collimation unit. This can also be achieved by a collimation unit whose refractive power is variable and can thus be controlled accordingly.
[0051] A light-affecting means which comprises a light source array with displaceable light sources and a corresponding collimation unit can at the same time serve as a part of the illumination device that is used in conjunction with a transmissive light modulator.
[0052] Aberrations in the optical system can be compensated by controlling the brightness of individual light source points.
[0053] If individual light points of the controllable light source array have a clear distance to each other, then the visibility region can be tracked in large steps with them. The mean deflection angle a of a light source which is situated at a distance I to the object-side principal plane and at a distance a to the optical axis of the collimation unit is here α=arctan (a/1).
[0054] The centre ray of a light source which is situated 10 mm in front of the object-side principal plane of the collimation unit and which bas a lateral offset of 2 mm to its optical axis has an inclination of 11.3 degrees relative to the optical axis.
[0055] As has already been shown above, a light-affecting means can be made up of multiple components. The first and/or the second light-affecting means of the light modulator device can be composed of multiple light-affecting elements with which the beam direction and/or the position of the real or virtual light sources are changeable independently of each other.
[0056] Multiple electrically controllable deflection gratings with same direction of deflection can thus wholly or partly be connected in series in order to extend the maximum achievable deflection angle or to realise a separate deflection range. To achieve a two-dimensional deflection, one-dimensionally working light-affecting elements can be combined so to form a light-affecting means. This can for example be done in the form of a crossed arrangement.
[0057] Here, the individual light-affecting elements of a light-affecting means can also be based on different physical principles.
[0058] The system controller considers the deflection properties of each individual element, so that it is possible to compensate aberrations which occur in one element in one or more other elements.
[0059] By varying the extent of the position change of the light of the light source and/or the extent of the beam direction change in the first and/or second light-affecting means depending on the point of incidence of the light on the surface area of the light-affecting means, the function of a field lens can be realised to adjust the size of the visibility region in the observer plane, or the effect of a separate field lens can be modified.
[0060] By way of controlling this position or beam direction change across the surface of one or multiple light-affecting means through the system controller, the size of the visibility region can be changed variably and thus, for example, be adapted to a changed observer distance from the display, so that the visibility region stays larger than the diameter of the eye pupil but smaller than the eye separation.
[0061] For this, the system controller analyses the position and distance information which is provided by the eye position detection system and sets the computed changes in the deflection angles in the corresponding light-affecting means in addition to the lateral angles which define the position of the visibility region in the observer plane.
[0062] The change in the beam direction in the light-affecting means for rough tracking of the visibility region can comprise both diffractive and refractive light-affecting elements.
[0063] In an embodiment with static light source array, the individual lenses of the collimation unit have a controllable lens effect so that the focal length and/or the lateral position of the lens vertex can be modified. Such a controllable lens based on an electrowetting cell has been disclosed, for example, in the European patent EP 1579249 B1, the entire contents of which being fully incorporated herein by reference.
[0064] For beam deflection in large steps, volume gratings to which at least two holograms are written can preferably be used in the first light-affecting means. The required volume grating or a master grating for further copies can be made by way of writing the holograms with the desired entrance and exit distributions with the particular working wavelength. The holograms can also be written in an optical system which is substantially identical to the application system or which is included in the latter (in-situ exposure) in order to compensate aberrations of involved optical components as much as possible.
[0065] Volume gratings can be optimised for very narrow angles of incidence which only differ slightly from one another and/or for narrow wavelength ranges. Very high diffraction efficiencies of near 100% can be achieved with this set-up for phase holograms. Here, the volume gratings serve as angle filters, i.e. only the light of a small angular range is diffracted to the desired direction, and/or as a wavelength filters, where only light of a selected wavelength range is diffracted to the desired direction. Light of other angles or wavelengths is transmitted through the volume grating without being diffracted.
[0066] The Bragg condition must be satisfied and the refractive index modulation must be chosen accordingly in order to make sure that only one diffraction order, i.e. for example the first, the second or a higher diffraction order, occurs when light passes through the volume grating. If the refractive index modulation deviates from the optimum, then there will be a non-diffracted portion, i.e. a zeroth diffraction order, even if the Bragg condition is fulfilled.
[0067] Depending on the thickness of the volume grating and the maximum possible refractive index difference, it may here be necessary to illuminate the grating such that multiple beam interference occurs, i.e. that enough grating layers are passed by the individual light beams. This means that the minimum generated diffraction angle is not too small, that it is 30 degrees, for example. This can be achieved by illuminating the volume grating at an angle. A further upstream volume grating can effect a necessary preliminary deflection should the geometric arrangement require so.
[0068] The thicker the volume grating the greater is its selective effect.
[0069] Diffraction processes at volume gratings have been described by Herwig Kogelnik in his Theory of coupled waves (H. Kogelnik, “Coupled Wave Theory for Thick Hologram Gratings”, Bell Syst. Techn. J. 48 (1969) 2909-2947). A volume grating is considered thick if it has a Q factor
[0000] Q= 2π d λ/( n 0 Λ 2 )
[0000] that is greater than 10, where d is the thickness of the volume grating, λ the working wavelength of the light in vacuum, Λ the grating constant of the volume grating and n 0 the mean refractive power.
[0070] Instead of using a volume grating which is optimised for multiple angles of incidence and/or multiple wavelengths, multiple volume gratings with smaller range of functions can be combined in series, i.e. each volume grating deflects the light into a different direction or focuses it on a different point.
[0071] In addition to various exit angles, additional field lens functions can preferably be written to the volume grating during manufacture which limit the diameter of the visibility region in the observer plane.
[0072] Generally, angle division multiplexing allows different wave fields to be reconstructed. This corresponds with the principle of holographic reconstruction. This also allows field lenses with different focal lengths to be reconstructed. It can also be preferable to reconstruct plane waves which propagate into different directions, for example if there is a separate field lens.
[0073] Here, the foci of the field lenses which are generated by light distributions with different angles of incidence do not have to lie in the same plane as them. For example, light distributions with different vertical angles of incidence can generate a series of field lenses whose foci differ, for example, in the horizontal direction, in the horizontal and vertical direction or in the horizontal and vertical direction and in the focal plane.
[0074] To generate or support the function of a field lens, it is possible to divide the volume hologram into at least two sub-holograms which lie side by side and each of which satisfying for itself the Bragg condition with slightly different exit angle; i.e. the volume grating is divided into segments. The manufacture and working principle of such volume holograms as such is known, for example, from the German patents DE 19 700 162 B4 or DE 19 704 740 B4, the entire contents of both of which being fully incorporated herein by reference.
[0075] For selecting the individual directions which are written to the volume hologram there can be at least one horizontal and/or vertical displacing unit which controllably affects the light emitted by the light sources such that the angle of incidence and/or the point of incidence on the volume hologram are variable. This unit can here, for example, be part of the backlight unit for a transparent light modulator or part of a frontlight unit for a reflective light modulator. Here, the necessary displacement and/or tilt is set by the system controller based on the selected detected eye position. It can be realised in a known manner using mechanical, reflective, refractive or diffractive methods. If a flat illumination device is used, the input coupling angle into a plane waveguide can so be varied, for example.
[0076] Another preferred embodiment uses for each wavelength range, i.e. for example for the red, green and blue spectral range, multiple narrow-band light sources, which differ only slightly in their principal wavelength and which are chosen and activated selectively by the system controller in order to choose or to address the individual diffraction angles in the at least one volume grating. Such light sources can preferably be lasers, for example semiconductor lasers or narrow-band light-emitting diodes.
[0077] Here, the system controller can perform a colour correction of the information to be represented, depending on the selected narrow-band spectral ranges.
[0078] Both methods can be combined with each other, so that diffraction gratings for different angles of incidence and for different, closely neighboured wavelengths can be written to the at least one volume hologram.
[0079] In another embodiment, at least one polariser which is switched through the system controller is used in conjunction with at least one birefringent lens in the first light-affecting means for changing the beam direction in large steps. Such a system is known, for example, from document WO 03 015 424 A2 for 2D/3D switching in an autostereoscopic display, the entire contents being fully incorporated herein by reference.
[0080] Here, a birefringent material, for example a liquid crystal mix, is disposed between two interfaces of two transparent materials which serve as substrate. In this arrangement, at least one interface is curved so to realise the effect of a lens and/or partly inclined in respect to the other interface so to realise the effect of a wedge.
[0081] One out of two possible lens and/or deflection effects can be selected by choosing one out of two possible directions of polarisation by the switchable polariser. The strength of the lens effect and/or of the wedge angle can vary across the surface area of the deflection and/or focusing unit. It is further possible to provide the switchable polariser in a segmented form so to be able to select the two directions of polarisation locally differently.
[0082] The switchable polariser can, for example, be formed by a variable retardation plate with the help of an electrically controllable birefringent material, which can, for example, comprise a liquid crystal mix as well. Here, the birefringent material is embedded between two substrates which are fitted with suitable electrode structures. It is possible here again to connect multiple of those light-affecting elements in series in order to increase the total effect of the light-affecting means.
[0083] Switchable birefringent light-affecting elements can also be used instead of a switchable polariser and a static birefringent light-affecting element. In such a device, as has been proposed, for example, for 2D/3D switching in autostereoscopic displays in document WO 2007/007 285 A2, the entire contents of which being fully incorporated herein by reference, the number of required substrates can be reduced compared with the aforementioned solution. These light-affecting elements can also be segmented and/or arranged in series connection.
[0084] Thanks to suitable electrode structures, plane light-affecting elements can thus also be manufactured where by impressing suitable electric field distributions a controllable gradient index profile of the refractive index can be generated with which the direction of light propagation can be influenced.
[0085] In further embodiments, at least one polarisation grating is used to affect the light. Such a grating only generates the −1 st , 0 th and +1 st diffraction order. Here, by using incident circular polarised light is its possible to deflect almost 100% of the light into the +1 st or −1 st diffraction order, depending on the direction of rotation of the circular polarisation.
[0086] Both actively switching polarisation gratings and passive polarisation gratings are known in the art. Polarisation gratings can be manufactured by way of aligning liquid crystals with adequately prepared surfaces. Such surfaces which serve as structured alignment layers for the liquid crystals can be generated, for example, by polymerising linear photo-polymerisable polymers (LPP). For this, the layers are formed, for example, with interference patterns of circular polarised ultraviolet light, e.g. as emitted by a UV laser.
[0087] Without or with only little voltage impressed on an electrode structure, the active polarisation gratings form a periodic grating structure and can deflect incident circular polarised light at high diffraction efficiency into the +1 st or −1 st diffraction order, depending on its direction of rotation. If the applied voltage is sufficiently high, the liquid crystals can be aligned such that the grating structure is destroyed, so that incident light passes through such a light-affecting element without being deflected, i.e. in the 0 th diffraction order.
[0088] Passive gratings can, for example, be made by way of polymerising liquid crystal polymers (LCP). Both active and passive polarisation gratings can be used in conjunction with a switchable polariser, for example with a switchable retardation plate, in order to select the desired diffraction order. In an active polarisation grating, the system controller controls both the switchable polariser and the controllable grating in order to select the desired direction of diffraction. In a passive grating, it is only the switchable polariser that is controlled for this. It is possible to connect multiple combinations of switchable polarisers and polarisation gratings as light-affecting means in series. The grating constant of the polarisation grating can be varied across the light entrance surface in order to achieve a locally different deflection effect. This variation can be continuous or segmented. This makes it possible, for example, to realise or to support the function of a field lens. It is also possible, for example, to implement cylindrical lenses or crossed cylindrical lenses.
[0089] In order to enable the system controller to select the actually suitable diffraction angle, the planar switchable polariser can also be of a structured design.
[0090] If the grating is used in conjunction with other light-deflecting elements, for example with an upstream field lens and/or other light-affecting elements, the grating must be optimised locally for a particular angle of light incidence. In an active polarisation grating, this can be done by way of local adaptation of the control voltage and thus of the effective birefringence.
[0091] In passive polarisation gratings, the hologram which is used during manufacture must show a local variation in the grating period.
[0092] In a simple polarisation grating, the deflection angle depends on the wavelength. In a colour display, where the individual colour components are generated by way of time division multiplexing, this angle difference must be compensated by the system controller using further controllable deflectidn elements.
[0093] Document WO 2008/130 561 A1, the entire contents of which being fully incorporated herein by reference, also discloses, for example, multiple layer systems of passive polarisation gratings, where the deflection angle remains almost constant across a wide spectral range.
[0094] In another embodiment, diffractive gratings whose grating period can be modified by changing the voltage impressed on a liquid crystal cell are used for rough light deflection. Such a system is described in U.S. Pat. No. 6,188,462 B1, for example, the entire contents of which being fully incorporated herein by reference. By varying the applied voltage across the surface of the grating, it is possible here too for the system controller to set a locally different deflection angle in a variable way.
[0095] Diffractive phase gratings of the kind provided to realise continuous deflection in the second light-affecting means can preferably be used for rough light deflection as well. In these gratings, the grating periods and thus the size of the deflection angle are set by impressing a saw-tooth-shaped voltage profile on a fine electrode structure, i.e. the control voltage rises from electrode to electrode from a base value to a peak value within a desired or specified grating period. Here, the peak value determines the maximum phase shift of the light which is modulated by the liquid crystal layer. Here, the voltage profile does not necessarily have to have a clear-cut saw-tooth shape, but should rather allow for the characteristic of the voltage-phase relation so to eventually achieve a saw-tooth-shaped phase profile. The smallest possible grating period, and thus the largest possible deflection angle, is defined by the electrode pitch. Since very fine grids with a pitch of few micrometres to several hundred nanometres are difficult to be controlled, in particular in large-area deflection gratings, it is possible to combine electrodes in the deflection grating for rough deflection and to address these groups of electrodes with a common signal if their distance is larger than that which corresponds with the grating period for the largest possible deflection angle in the deflection grating for fine deflection. The deflection grating for fine deflection can, for example, have an electrode pitch of several micrometres, with each electrode being addressed individually, whereas the deflection grating for rough deflection has an electrode pitch of less than one micrometre but where electrodes are combined over a width that is larger than the electrode pitch of the deflection grating for fine deflection.
[0096] Here, combining the electrodes can be segmented across the surface of the deflection grating. It is also possible to vary the electrode pitch across the surface of the grating, e.g. to provide a finer electrode grid near the edges of the grating so to realise a larger deflection angle which is required there.
[0097] Further light-deflecting elements can preferably be used in a transmissive or reflective mode for beam deflection of pencils of rays with small cross-section, as they are emitted by small light sources in the illumination device directly or after beam forming. Acousto-optic modulators (AOM), for example, allow beam deflection at high speed. Here, the deflection angle can be changed by varying the control frequency. The diffraction efficiency can be affected by varying the level of the control voltage. AOMs which comprise multiple sound converters which can be controlled with phase-shifted signals are also known. Thereby, the effective phase grating in the AOM can be inclined depending on the phase and thus be adapted to changing exit angles so that the Bragg condition is widely satisfied at the same angle of incidence in order to realise a high diffraction efficiency at a wide exit angle range and a wide working wavelength range. Such a modulator is known for example from document U.S. Pat. No. 5,576,880, the entire contents of which being fully incorporated herein by reference. Since an AOM only allows small deflection angles to be generated, the angular range can be extended by way of providing downstream a volume grating with multiple exit angles written to it or a respective volume grating stack comprising individual gratings with different exit angles at angles of incidence which differ only slightly. Such an arrangement is known for example from document U.S. Pat. No. 3,980,389, the entire contents of which being fully incorporated herein by reference.
[0098] All optical interfaces of the light-affecting means or light-affecting elements should preferably be fitted out with anti-reflection layers to prevent the occurrence of diffused light. They can have a broad or narrow spectral and/or angular bandwidth, as is known in the prior art, depending on the actual application.
[0099] Suitable apertures for filtering out diffused light and/or diffraction orders which are not used can be disposed in the optical path. Additional means for wave front forming, such as apodisation masks, can be used as well.
[0100] Further possible measures for optimising and specially adapting the method, including, for example, the use of look-up tables to allow fast computation of the control parameters for the deflection angles, the use of joint substrates in a multi-layer design of light-deflecting elements, measures for calibration, error correction, compensation of thermal effects, compensation of ageing effects or the design of the control circuitry and electrode structures shall be included in the present invention and will not be explained in more detail because such measures are apparent to a person who is skilled in the art and knows the teaching of the invention described above. All controllable components can also be designed to provide closed-loop control in conjunction with suitable additional sensing devices.
[0101] Other known light-deflecting elements than the mentioned electrically controllable diffraction gratings can be used as well for continuous observer tracking.
BRIEF DESCRIPTION OF THE DRAWINGS
[0102] Now, there are a number of possibilities for embodying and continuing the teachings of the present invention. To this end, reference is made on the one hand to the dependent claims that follow claim 1 , and on the other hand to the description of the preferred embodiments of this invention below including the accompanying drawings. The Figures are schematic drawings, where
[0103] FIG. 1 shows a first embodiment of the invention,
[0104] FIG. 2 shows a detail of a light-affecting means for observer tracking in large steps with the help of switchable light sources,
[0105] FIG. 3 shows a light-affecting means for observer tracking in large steps with the help of switchable light sources with additional field lens function,
[0106] FIG. 4 shows a detail of a light-affecting means for observer tracking in large steps by way of light source displacement with the help of diffractive deflection gratings in the illumination device,
[0107] FIG. 5 shows a detail of an illumination device with a volume grating and angular multiplexing,
[0108] FIG. 6 shows a light modulator device with a reflective light modulator,
[0109] FIG. 7 illustrates the generation of two field lenses with the help of an active liquid crystal grating,
[0110] FIG. 8 shows a light modulator device with a transmissive light modulator and a liquid crystal phase grating with controllable grating period in conjunction with a multiplex field lens,
[0111] FIG. 9 shows a flat backlight device which allows vertical and horizontal displacement of the wave field which is generated by a collimation unit before it enters a first volume grating,
[0112] FIGS. 10 a to 10 c show exemplary effects of two controllable volume gratings as vertical light-affecting elements in FIG. 9 , and
[0113] FIG. 11 shows a light modulator device with a transmissive light modulator and a polarisation grating in conjunction with a switchable polariser.
DETAILED DESCRIPTION OF THE INVENTION
[0114] FIG. 1 shows schematically a typical embodiment of a light modulator device. A light source 100 , here a plane light source array, comprises a multitude of individual small light sources 101 to 123 which are switchable or whose brightness is controllable in an open or closed-loop control process individually or in groups through a system controller 900 .
[0115] Here, each single light source 101 to 123 can also comprise multiple light sources with different principal wavelengths which are also be independently controllable. The light sources 101 to 123 illuminate a plane light modulator 400 through a collimation unit 200 , which can comprise an array of individual lenses 201 to 203 or stripes of cylindrical lenses. The lenses 201 to 203 can also be of a controllable type, so that the focus is variably controllable in one, two or three dimensions by the system controller 900 . The device can comprise an aperture stop 250 which prevents light emitted by one of the light sources 101 to 123 from passing through multiple lenses 201 to 203 of the collimation unit 200 . This is of particular importance if the device is designed for multi-user operation. In the embodiment illustrated in FIG. 1 , a transmissive light modulator 400 is used which modifies the amplitude and/or phase of the light in the plane. The combination of the controllable light source array 100 and the collimation unit 200 forms a dynamic illumination device 300 .
[0116] The light modulator 400 receives its modulation values for the display of three-dimensional image information from the system controller 900 , which computes these values based on input information of the 30 scene 902 and on position information of at least one eye position 1100 of at least one observer of the image information, said position information being provided by an eye position detection system 800 . The system controller 900 allows for the characteristics of the light modulator 400 and takes into consideration further correction values which result from the specific design of the optical system and from the position information. The image information to be displayed, in particular the scene detail to be represented, can also be prepared outside of the system controller 900 based on the eye position information 901 which is made available by the system controller 900 to an external computing unit. The eye position detection system 800 , which is known as such in the art, can comprise, for example, at least one camera and a corresponding signal processing unit, where the signal processing unit can also be part of the system controller 900 . The signal processing unit finds the position of the eye pupils in the particular camera image and calculates the corresponding spatial coordinates of all observer eyes 1100 . Other eye position detection systems 800 , which work, for example, with ultrasound, or which use passive or active marks or signal sources which are associated with the observer can be used as well.
[0117] Further light-affecting means 501 , which are controlled by the system controller 900 , can be disposed in the optical path between the light sources 101 to 123 and the observer eyes 1100 . In the illustrated embodiment, the dynamic illumination device 300 —alone or in combination with the further light-affecting elements 501 —forms the light-affecting means 500 for rough beam deflection. A second light-affecting means 600 is provided in the form of diffractive controllable deflection gratings, where said light-affecting means can also comprise multiple light-affecting elements, in order to direct the particular visibility region 1000 continuously or in fine steps at the particular observer eye as controlled by the system controller 900 based on the eye position information 901 . Referring to the embodiment pictured in FIG. 1 , a field lens 700 is provided for focusing the visibility region 1000 on the observer plane, where said field lens can also be designed in the form of a controllable adaptive lens which is controlled by the system controller 900 to adjust the size of the visibility region 1000 depending on the distance of the observer eyes 1100 from the light modulator 400 . The function of the field lens 700 can, however, wholly or partly be integrated into the dynamic illumination device 300 and/or into further light-affecting elements 501 and/or into light-affecting elements of the second light-affecting means 600 .
[0118] FIG. 2 shows schematically a detail of an illumination device which is designed such to serve as a light-affecting means for rough tracking of at least one visibility region to the position of at least one observer eye using switchable light sources 101 to 103 .
[0119] A multitude of switchable or controllable light sources 101 , 102 , 103 are situated in front of a collimation unit 200 , which can comprise refractive and/or diffractive elements. The desired direction of deflection is selected by switching on one of the exemplarily shown light sources 101 , 102 or 103 . The deflection angle depends on the distance of the light source to the optical axis OA of the segment of the collimation unit 200 and on its distance to the object-side principal plane of these image segments. In the illustrated embodiment, the light sources 101 to 103 are situated in the object-side focal plane, so that the light leaves the collimation unit 200 parallel. This light illuminates the light modulator 400 .
[0120] FIG. 3 shows schematically an option for observer tracking in large steps with the help of switchable or controllable light sources 101 to 123 with additional field lens function. The individual light sources 101 to 123 of a light source 100 which is provided in the form of a plane light source array are arranged asymmetrically behind the collimation lenses 201 to 203 of a collimation unit 200 , so that the light which is emitted by the light sources 101 to 123 and which passes through the light modulator 400 is deflected more strongly towards the centre of the observer region of the display device near the edges of the light modulator 400 than light which is emitted by light sources in the centre of the collimation unit 200 . As shown here, the light sources 101 to 123 can be arranged outside the focal plane of the collimation lenses 201 to 203 , so that they are imaged to the central observer plane.
[0121] The individual light sources 101 to 123 can be composed of individually switchable or controllable sub light sources with different spectral distributions of the emission characteristics. The individual sub light sources can be slightly staggered in depth, i.e. located at different positions in relation to the optical axis, so to compensate chromatic aberration of the collimation unit in order to allow all colour components to be imaged largely in the same central observer plane.
[0122] For this purpose, the refractive power of the collimation lenses 201 to 203 can, for example, be variably changeable by the system controller in order to compensate such chromatic aberration and to adjust the observer plane to the distance of the observer from the display device.
[0123] There are a number of further possibilities to realise the function of a field lens. The optical axes of the individual collimation lenses 201 to 203 could, for example, be inclined more strongly towards the edge of the lens array 200 , so that, for example, all optical axes intersect in the centre of the observer region in the central observer plane. The light sources 101 to 123 which are assigned to a certain lens 201 to 203 can be disposed at an angle too.
[0124] FIG. 4 shows the principle of the observer tracking using diffractive gratings with the example of a detail of an illumination device. A collimated light source 101 illuminates a switchable or controllable light-affecting element 501 for beam deflection, which can comprise, for example, at least one diffractive deflection grating. The latter deflects the beams of the collimated light source 101 to a different location on a diffusing plate 110 , depending on the set deflection angle. The diffusion profile can be varied locally such that the following collimation lens 201 , which can comprise, for example, diffractive and refractive elements, is illuminated as optimally as possible. The locally varied diffusion profile of the diffusing plate 110 can, for example, be generated holographically. The points of incidence of the pencils of light which are deflected by the light-affecting element 501 represent deflection-angle-dependent secondary light sources 111 to 113 , which illuminate a region of the light modulator through the collimation lens 201 of a collimation unit, as shown in FIG. 2 or FIG. 3 . The light source 101 can again comprise individually switchable sub light sources with different spectral distributions of the emission characteristics. The light-affecting element 500 can be composed of multiple deflection gratings in order to provide for a two-dimensional deflection, for example. Suitable aperture stops 250 can prevent light of unused diffraction orders, which can occur in the light-affecting element 501 , or light of the secondary light sources 111 to 113 which does not fall on the collimation lens 201 from illuminating other collimation lenses of the collimation unit and from propagating though the illumination device as unwanted stray light.
[0125] Controllable diffractive gratings whose grating period can be controlled variably can preferably be used as deflection gratings in the light-affecting element 501 .
[0126] Phase gratings which are based on liquid crystal cells can, for example, be used where variable grating periods and thus deflection angles are writable with a grid electrode structure.
[0127] Moreover, acouto-optic modulators can be used as well.
[0128] However, further embodiments are possible, including the use of active and passive polarisation gratings in conjunction with controllable retardation plates.
[0129] Since the distance between the light-affecting means 501 and the diffusing plates 110 can be chosen rather large, it is possible to use in the light-affecting means 501 deflection gratings which can only generate small deflection angles. Only low demands will thus be made on the required minimum grating period, which simplifies the manufacture of such deflection elements considerably.
[0130] The controllable grating can be illuminated at an angle in order to blank out undesired intensities in the zeroth diffraction order. In order to realise an optimum deflection range for each working wavelength, where said deflection ranges are largely overlapping, the grating can be illuminated at a different, adapted angle for each working wavelength range.
[0131] Instead of the deflection grating in the light-affecting element 501 , other deflection elements can be used as well. Controllable electro-wetting cells can be used, for example, where the position of a meniscus or the position and shape of a meniscus as an interface of two liquids with different refractive index can be varied in one or two directions.
[0132] FIG. 5 shows schematically a detail of an illumination device with a volume grating and angular multiplexing of the light sources. The light-affecting element 501 , which comprises at least one volume grating 502 for light affecting, is illuminated from slightly different directions by multiple light sources 101 to 103 through collimation lenses 201 to 203 . Various reconstruction geometries are statically written to the volume grating 502 of the light-affecting element 501 . If the volume grating is illuminated from different directions, different wave fronts are generated and emitted. The volume grating 502 of the light-affecting element 501 , which can also comprise a stack of multiple volume gratings 502 , can, for example, be illuminated at five angles with an increment of 0.3°, so that on its exit side five field-lens wave fronts are generated with an angle increment of 12°, for example.
[0133] FIG. 6 shows schematically a light modulator device with a reflective light modulator 400 for image encoding in conjunction with a frontlight unit. The frontlight unit for illuminating the light modulator 400 with collimated light comprises a stack of plane light-deflecting elements 510 , 520 . Here, the corresponding deflection function can be selected by activating a light source 110 , 120 which is assigned to the particular light-deflecting element 510 , 520 . In this embodiment, the light sources 110 , 120 are each represented by a laser diode 111 , 121 for the red spectral range, a laser diode 112 , 122 for the green spectral range and a laser diode 113 , 123 for the blue spectral range. The light which is emitted by these light sources 110 , 120 passes accordingly assigned collimation units 210 , 220 and is coupled into a plane waveguide 513 , 523 through at least one volume grating 511 , 521 each, where each combination of volume grating and plane waveguide is disposed on a joint substrate 514 , 524 . In this embodiment, a hologram each for the red, green and blue spectral range are written to each of the volume gratings 511 , 521 . In optically coherent applications, for example in a holographic display device, the plane waveguide 513 , 523 should be chosen to be so thin that light can propagate under one reflection angle only (mono-mode light waveguide) in order to maintain the coherence of the light.
[0134] The light is coupled out of the plane waveguide 513 , 523 through the accordingly assigned volume grating 512 , 522 and directed in a collimated manner at the reflective light modulator 400 . After being modulated by the reflective light modulator 400 , the light of the selected light source 111 to 113 , 121 to 123 , is deflected by the corresponding volume grating 512 , 522 into the desired direction or, as shown here in this embodiment, focused on the desired location in the observer plane. In this embodiment, holograms for each working wavelength of the light sources 110 , 120 are written to the volume gratings 512 , 522 too. These holograms are made such that a homogeneous luminous intensity is generated across the entire surface of the light modulator 400 . For this, the diffraction efficiency must be the higher in the volume grating 512 , 522 the farther the output coupling point is away from the corresponding input coupling grating 511 , 521 .
[0135] At least one additional light-deflecting element 600 , which works continuously or in fine steps, ensures that, depending on the position of the observer, light can also be directed at eye positions which do not coincide with the fixed focusing points of the holograms which are written to the volume gratings holograms 512 , 522 . Here, the deflection element 600 can support the function of a field lens or fully take on this function. Alternatively, a separate field lens can be disposed, for example, between the light-deflecting element 600 and the observer.
[0136] The collimation units 210 , 220 , which are assigned to the light sources 110 , 120 , can comprise passive and/or active optical elements 211 , 212 , 221 , 222 for beam forming and beam direction changing, where said elements can affect the light reflectively, diffractively and refractively. Moreover, they can comprise scanning components, for example in order to illuminate the input coupling volume gratings 511 , 521 in stripes. FIG. 7 shows schematically another embodiment of the invention. Here, one out of two field lenses which are written to a static volume grating 533 can be selected by a controllable volume grating 532 as controlled by a system controller (not shown in FIG. 7 ). A reflective phase-modulating light modulator 400 , which is illuminated with collimated light by a frontlight unit 300 , generates a modulated phase distribution which carries the image information to be represented. A spatially amplitude- and phase-modulated wave front 450 is generated by combining the light which has been modulated by neighbouring pixels of the phase-modulating light modulator 400 in a beam combiner 410 , said wave front reconstructing the objects to be represented in the reconstruction space. Here, the object points can be reconstructed really between the observer and the light modulator 400 and virtually behind the light modulator 400 . The modulated wave front 450 is deflected by a defined angle by the static volume grating 531 in order to generate a suitable or optimal angle of incidence for the following controllable volume grating 532 . Here, the exit angles of the individual narrow-band wavelength ranges of the light sources of the frontlight unit 300 can differ slightly from each other. Depending on how the controllable volume grating 532 is controlled, the light passes through the latter without being diffracted or is diffracted by its grating structure into the first diffraction order. Said controllable volume grating 532 can be, for example, a polymer dispersed liquid crystal grating. Here, the desired diffraction pattern is created during manufacture by way of local polymerisation when a hologram is inscribed. Depending on the voltage impressed on the electrode structure, the refractive index difference among individual grating elements can be controlled in such gratings. If the voltage is chosen such that there is no refractive index difference, then the light will pass through the grating without being diffracted. The refractive index difference in the grating can be chosen by impressing a suitable voltage on the electrodes such that almost all light of the currently processed reconstruction wavelength range is diffracted into the first diffraction order.
[0137] A static volume grating 533 , which can also be provided in the form of a multiplex volume grating, focuses the selected direction on the focal region 1001 or 1002 , respectively. Here, the different angles of incidence for the individual wavelength ranges can also be allowed for, so that the focal regions of the individual colour components form a joint focal region.
[0138] It is also possible to vary the diffraction angles in the gratings 531 and/or 532 locally in order to get a suitable local angle of incidence for the volume grating 533 so that the required diffraction angle can be set in this grating at high diffraction efficiency. A segmented arrangement can be used here, too. This arrangement can also be applied to amplitude-modulating light modulators and complex-valued light modulators. Moreover, transmissive modulators can be used as well, then in conjunction with a backlight unit. In an autostereoscopic display, it is thus possible, for example, to switch between the focal points for the left and right observer eye. Typically, the arrangement is followed by a light-affecting means for continuous tracking of the foci to the observer position (not shown).
[0139] FIG. 8 shows schematically an embodiment of a light modulator device with at least one transmissive phase-modulating light modulator 400 for encoding image information in conjunction with a controllable liquid crystal phase grating 541 . The light modulator 400 is illuminated with sufficiently coherent light by a backlight unit 300 . After having been modulated by the light modulator 400 , the light is formed into a spatially amplitude- and phase-modulated wave front 450 in at least one beam combiner 410 . This wave front hits at least one controllable liquid crystal phase grating 541 for step-wise deflection of the wave front. For this, the liquid crystal phase grating 541 comprises a multitude of electrodes which can be addressed individually or in groups with a variable voltage profile. A Bragg grating is created in the liquid crystal grating by impressing a saw-tooth-shaped voltage profile with variable period lengths and variable voltage spikes on the electrode structure. Due to the saw-tooth-shaped phase profile which is thus generated by the grating, this grating acts as a blazed grating for the set direction of deflection if both grating period and phase shift are adapted to the currently processed working wavelength. As a consequence, the light of the wave front is diffracted into the desired direction of deflection at high diffraction efficiency.
[0140] Generally, the liquid crystal phase grating 541 can generate discrete or continuously variable angles for three wavelengths, for example.
[0141] In the following field lens, which can include a thin volume grating 542 and which comprises a thick volume grating 543 , one of the focal regions 1001 to 1005 which are written to the thick volume grating 543 is selected by the deflection angle that is chosen by the liquid crystal phase grating 541 . Here, the thin volume grating 542 , if provided, diffracts the light which comes from the liquid crystal phase grating 541 such that for the at least one thick volume grating 543 an optimal or suitable angle of incidence is generated so that the light can be diffracted at high diffraction efficiency in the liquid crystal phase grating 541 .
[0142] A light-affecting means 600 , which comprises at least one finely structured diffractive liquid crystal phase grating, serves as a light-affecting means for tracking the selected focal region 1001 to 1005 continuously or in fine steps to the position of the selected observer eye as controlled by the system controller (not shown in FIG. 8 ). The visibility region from which the reconstruction can be viewed by the selected observer eye is thus generated.
[0143] FIG. 9 shows schematically a light-affecting means for rough beam deflection, said light-affecting means being integrated into a flat backlight unit. A light source 100 illuminates a collimation unit 220 through a beam widening system 210 . Here, the light source 100 can, for example, comprise an individually controllable laser diode each for the red, green and blue spectral range. The light which is collimated by the collimation unit 220 is directed at the apertures of an aperture stop 120 by corresponding lenses of a lens array 230 . The apertures have the function of secondary light sources and the aperture stop thus forms a light source array. Further optical components 110 which serve to condition the light which is emitted by the light source 100 can be disposed in the optical path. At least one moving diffusing plate for reducing disturbing speckle effects can be disposed here, for example, which modulates the coherent laser radiation with a random phase. A light source array which comprises, for example, a multitude of laser diodes of the desired wavelength ranges can also be used instead of the single light source 100 and the aperture stop 120 . The individual secondary light sources of the aperture stop 120 are collimated in another lens array 240 and illuminate a first light-affecting element 550 for beam deflection in the vertical direction. Further optical components 130 which serve to condition the light which is emitted by the secondary light sources 120 can again be disposed in the optical path. For example, at least one static or moving diffusing plate can be provided to limit the spatial coherence on the exit surface of the backlight to a suitable degree, so that, for example, multiple sub-holograms to be represented do not influence each other. A second light-affecting element 560 can affect the light in the horizontal direction. It is also possible that the light-affecting elements 550 , 560 affect the light in another direction than the horizontal or vertical direction, or that they are arranged in a different order. Moreover, the light-affecting elements 550 , 560 can be combined in one light-affecting element with a two-dimensional light-affecting effect. The light which is emitted by the light-affecting means 550 passes through a light waveguide 260 and illuminates a first volume grating 570 . The latter directs the light through another light waveguide 270 at a second volume grating 580 . Depending on the angular distribution of the light, with its selected wavelength distribution, generated in the controllable light-affecting elements 550 , 560 , the angular range desired for illuminating a light modulator (not shown here) is selected by the volume holograms which are written to the volume gratings 570 and 580 . Here, the angular distribution by the light-affecting elements 550 , 560 can be dimensioned such that the entire modulator surface is illuminated at a uniform brightness. The diffraction efficiency of the volume gratings 570 , 580 can vary locally for this, as described above.
[0144] The light waveguides 260 and 270 should preferably be made of the same material, whose refractive power should differ as little as possible from that of the corresponding volume gratings 570 and 580 , in order to avoid reflections at the interfaces. One or both light waveguides 260 , 270 can also be of a wedge-shaped design. However, they can also be made of a different material, for example air. In this case, the interfaces may have to be treated with an anti-reflective coating.
[0145] The volume gratings 570 and 580 simultaneously effect an anamorphic enlargement of the illuminating wave field which is generated by the secondary light sources 120 and collimated by the lens array 240 . It is thus possible to use small light-affecting elements 550 , 560 for the selection of the hologram functions which are written to the volume gratings 570 and 580 . They can be manufactured more easily and at lower costs than large-area arrangements. Moreover, small-area controllable deflection gratings can be designed to have a smaller grating constant, so that greater diffraction angles are generatable.
[0146] Further optical components, such as optical fibres or tilted mirrors can be disposed in the optical path between the light source 100 and the light waveguide 260 , for example in order to allow a compact design of the entire system.
[0147] FIGS. 10 a to 10 c show schematically a possible arrangement and three possible effects of a light-affecting element from the embodiment that was illustrated in FIG. 9 with the example of the light-affecting element 550 for vertical deflection.
[0148] Two controllable liquid crystal gratings 551 , 552 , which are disposed immediately one after another, serve as a vertical displacing unit to affect the incident wave front 150 and to transform it into an exit wave front 160 .
[0149] In the example that is illustrated in FIG. 10 a , the two controllable liquid crystal phase gratings 551 and 552 generate both a vertical displacement and a change in the angle of the direction of propagation of the wave field 150 .
[0150] The example which is illustrated in FIG. 10 b demonstrates an expansion and displacement of the centre of the wave field 150 .
[0151] The example which is illustrated in FIG. 10 c shows a displacement and locally varying change in the exit angle of the wave field 150 .
[0152] FIG. 11 shows schematically an embodiment of a light modulator device where the visibility region for the reconstruction of the 3D scene is tracked in large steps to the observer eye positions with the help of a passive polarisation grating in conjunction with active polarisation-modifying light-affecting elements.
[0153] A phase-modulating light modulator 400 , which is illuminated with sufficiently coherent light by a backlight unit 300 , and on which the scene to be reconstructed is encoded, generates together with a beam combiner 410 a spatially amplitude- and phase-modulated wave front 450 . The light of the wave front 450 is given a left-handed or right-handed circular polarisation by a switchable or controllable polariser 591 , which is provided, for example, in the form of a switchable or controllable retardation plate, and is directed at the following polarisation grating 593 . The polarisation grating 593 diffracts the light—depending on the polarisation direction—to the +1 st or −1 st diffraction order, respectively, at high diffraction efficiency. Here, a volume hologram 592 is disposed between the switchable polariser 591 and the polarisation grating 593 , said volume hologram 592 diffracting the light which passes through the switchable or controllable polarisation-modifying element locally into a direction which corresponds with a suitable angle of incidence for the polarisation grating 593 .
[0154] A polarisation-modifying element 594 , which can also be of a switchable or controllable type, can be disposed behind the polarisation grating 593 in order to suppress light which is not deflected into the desired diffraction order.
[0155] A following light-affecting means 600 for deflecting the light continuously or in fine steps directs the light of the modulated wave front 450 at the eyes of the observer, so that the latter can watch the reconstructed 3D scene.
[0156] The arrangement can comprise further passive or active polarisation-modifying elements which set the required polarisation direction for following polarisation-dependent elements or to transform linear polarised light into circular polarised light or vice versa.
[0157] The embodiment has a passive polarisation grating 593 whose grating period varies locally continuously or in steps. This makes it possible, for example, to realise the function of a field lens. If the light-affecting means 600 is in its neutral position, the light of the wave front 450 is directed at one of the two visibility regions 1001 or 1002 , depending on the status of the switchable or controllable polarisation-affecting elements 591 or 594 .
[0158] One or both switchable or controllable polarisation-affecting elements 591 or 594 can also be structured locally and switchable or controllable separately in one or two directions in order to compensate effects caused by the passage angle and/or of the wavelength range of the currently transmitted light.
[0159] Polarisation gratings 593 with uniform grating constant can be used too. They deflect the light of the modulated wave front 450 into one out of two directions, which are defined by the +1 st and −1 st diffraction order, respectively, depending on the status of the polarisation-modifying element 591 . The function of a field lens can then be realised by additional passive and/or active optical elements, for example volume gratings.
[0160] In stacks which comprise locally controllable polarisation-modifying elements 591 , 594 and passive polarisation gratings 593 , the effect the deflection angle of the elements 591 , 593 , 594 of stack layers which are disposed more upstream in the optical path has on the polarisation change in the respective polarisation-modifying element 591 , 594 can be compensated in a wavelength-specific manner through these locally controllable polarisation-modifying elements 591 , 594 . Polarisation-modifying elements 594 , 591 which are disposed one after another and which belong to different neighbouring stack layers can also be combined so to form a joint controllable polarisation-modifying element.
[0161] Such stacks can be used to generate more than two focal regions or directions of deflection. The polarisation gratings 593 in the stack layers preferably have different grating constants at the same horizontal and vertical position, thus generating different diffraction angles there, in order to realise steps that are as uniform and fine as possible so to prevent double focal regions.
[0162] The number of layers in such a stack can be kept small by using polarisation gratings 593 with controllable grating period.
[0163] With switchable polarisation gratings 593 , the zeroth diffraction order can be used as well.
[0164] Polarisation gratings 593 which exhibit a diffraction efficiency of almost 100% through a wide wavelength range can be manufactured by finding a suitable combination of the layer thickness, and thus of the optical retardation, and the twisting angle of the liquid crystal molecules. However, it is also possible to use stacks of switchable polarisation gratings 593 with each element being optimised for a different wavelength range.
[0165] In colour division multiplex mode, it is then possible to only activate the grating which is optimised for the currently processed spectral range.
[0166] A complex-valued light modulator can be used as an alternative to a phase-modulating light modulator 400 and a beam combiner 410 . Further, it is possible to use a reflective light modulator in conjunction with a frontlight unit.
[0167] In the mentioned embodiments, it is also possible to use light modulators which generate the hologram through a scanning device or to use multiple light modulators. Moreover, a holographic or autostereoscopic display can also comprise multiple separate light modulator devices which jointly reconstruct a 30 scene or which jointly generate a stereoscopic image.
[0168] In all embodiments, all active components can be controlled by a system controller based on observer eye position information which is determined by an eye position detection system, while aberrations of optical components, thermal effects, local deviations of the wave front form caused by brightness fluctuations in the illumination device 300 and modulation errors in the light modulator 400 , for example, can be widely allowed for and compensated. If necessary, such aberrations can be quantified in calibration measurements or found actively in real-time measurements.
[0169] Finally, it must be said that the embodiments described above shall solely be understood to illustrate the claimed teaching, but that the claimed teaching is not limited to these embodiments.
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For comfortable viewing of a 3-D scene at various viewing angles, a display having a large tracking range for a variable viewer distance is required. A controllable light-influencing element deflects light in coarse steps in a viewer range. Within said steps, the light is deflected by a further controllable light-influencing element continuously or with fine gradation. The light modulation device is suitable in holographic or autostereoscopic displays for guiding the visibility ranges of the image information to be displayed so as to follow the eyes of the viewers.
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RIGHTS OF THE U.S. GOVERNMENT
The government of the United States of America has certain rights to this invention pursuant to National Science Foundation Grant No. INT 8520639.
This is a divisional of copending application(s) Ser. No. 07/210,259 filed on June 23, 1988, now U.S. Pat. No. 4,985,612.
PRIORITY
Priority is claimed of Bulgarian Authorship (Patent) application filed under Ser. No. 81312 for "Method for Welding and Laminating Polyamides" on Sept. 29, 1987, in Sofia, Bulgaria.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method for welding and laminating polyamides applicable to the production of various articles widely used in the national economy.
2. Prior Art
It is known that polymer (including polyamide) laminate, can be obtained using special glues or bonding chemicals as well as dry self-bonding (e.g., of polyamide foils) at high temperatures under pressure (New Linear Polymers, H. Lee, D. Stoffery and K. Neville, McGraw-Hill Book Company (1967)).
The disadvantages of these methods are the requirements for the use of complex and expensive chemical compounds and high energy consumption. Furthermore, the bonding is not always satisfactory, and the bonding compounds are often deleterious with respect to the properties of the polymer used, e.g., they lower its thermal stability. Laminating of oriented foils at high temperature by self-bonding leads to a decrease in the degree of orientation and hence to deterioration of the physico-mechanical characteristics of the laminate obtained.
It is known that polyamide-6 can be crosslinked in the amorphous regions by methoxy-methylation (methylene bridges bond together the amide groups of neighboring macrochains) (1. Arakawa, F. Nagatoshi and N. Arai, J. Polym. Sci., Polym. Lett. Ed., 6 513-516 (1968)). For this purpose, polyamide is dipped into a solution of paraformaldehyde in methanol with the addition of small amounts of potassium hydroxide and anhydrous oxalic acid. After 30 hours at 30° C., the crosslinking agent penetrates into the polymer and reacts with the amide groups, making bridges of methylene groups.
Crosslinking improves the polymer strength but it has the following disadvantages. When carried out on polymer granules, the subsequent processing of the polymer will be hampered due to the rise of the viscosity of its melt. Moreover, since the penetration of the crosslinking agent into the polymer is a slow diffusion process, the methoxy-methylation of polyamide articles having a considerable volume can prove too time-consuming from the viewpoint of its application on an industrial scale.
DESCRIPTION OF THE INVENTION
The object of this invention is to provide a method for welding and laminating polyamides by creating a chemical bond between separate polyamide bodies and avoiding residual substances which could change the polyamide properties and the use of severe conditions (high temperature) which worsen the quality of the starting polymer material, especially in the case when the latter has been subjected to a preliminary orientation.
In this invention, welding (or lamination) of a polymer containing amide groups is carried out by the creation of methylene bridges between the nitrogen atoms of two closely situated amide groups. In this case, the methoxy-methylation reaction occurs between the contacting surfaces of two physically independent, separate bodies or substrates. The basis amide of the substrates may be alike or different and synthetic (polyamide-6, polyamide-12) or natural (protein, polypeptide).
The polyamide bodies are coated (wetted) with a methoxy-methylating solution of paraformaldehyde in methanol (paraformaldehyde:methanol from 0.1:1 to 1:5 to which traces of KOH are added); they are then pressed together (pressure of 0.05 to 5 MPa) in order to achieve a good contact between the surfaces and the solution. This operation is carried out at a temperature of 5 to 40° C. for 30 minutes to 36 hours. A measurable effect can be observed even after 30 minutes while after 36 hours weld is so strong that in a shear test the material breaks outside the welded area.
The advantages of the method according to the invention are as follows. Unlike the known methods, welding is not a mechanical one since it is based on the formation of a chemical bond and for this reason, it is very strong. The method does not require energy consumption since it can be carried out even without heating. An additional advantage is based on this fact: in the case of lamination of oriented foils, they preserve their oriented state and in all cases the polymer does not undergo any unfavorable changes caused by heating. Moreover, by using thin polyamide foils the formation of methylene bridges (crosslinking) takes place in the entire volume of the obtained laminate, regardless of its thickness. The proposed method is convenient and simple, it does not require expensive bonding compounds, it lacks a second material. Last but not least, an important advantage of the proposed method consists in the possibility of welding two, three or more physically different bodies even if they differ in their chemical nature, e.g., synthetic polyamides like polyamide-6, polyamide-12, etc., as well as natural proteins, e.g., animal membranes and polypeptides. The sole condition for the formation of a chemical bond according to the method of the present invention is the presence of amide groups (--CO--NH--) in the polymer macromolecule.
EXAMPLE
Oriented or isotropic polyamide foils (sheets) are coated (wetted) uniformly with a methoxy-methylating solution prepared as follows. Paraformaldehyde (75 g), and potassium hydroxide, (0.1 g) are added to 75 g of methanol. The mixture is heated at 60° C. until it gives a clear liquid. 6 g of anhydrous oxalic acid is then added as the catalyst of the reaction. Foils coated with the above mixture are pressed in a drill press vise and are stored there for 36 hours at a temperature of 30° C.
Having described our invention,
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Polyamide bodies, e.g., foils or sheets, are welding together or laminated by forming methylene bridges between nitrogen atoms in the separate bodies by pressing them together in the presence of a alkaline paraformaldehyde/methanol solution containing a catalytic amount of oxalic acid.
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FIELD OF THE INVENTION
This invention relates to novel, finely divided calcium carbonate compositions. More particularly, this invention relates to novel, aqueous or dried, finely divided, wet-ground, dispersant-free calcium carbonate filler or pigment compositions whose average mean particle size and particle size distribution have been adjusted to provide, when such compositions are used as fillers for paper, a balance of filler retention, opacity, brightness and strength characteristics hitherto unobtainable using available ground calcium carbonate fillers, particularly those containing dispersants, and approaching or in some cases equalling that obtainable using typical precipitated calcium carbonate compositions.
BACKGROUND OF THE INVENTION
Finely divided calcium carbonate has long been used by the paper/board industry, alone or more often with other materials, in high solids slurries or dispersions as an opacifying filler or pigment, and as a coating for paper. Many processes for grinding or comminuting calcium carbonate to give slurries or dispersions for these and other end uses, and the finely divided calcium carbonate products obtained thereby, have been described in the prior art. Typically such processes involve either horizontal wet micromedia milling, e.g., sand milling, usually carried out with the use of dispersants and followed by centrifuging, when necessary, to remove the coarsest particles, or vertical wet micromedia milling, usually but not invariably in the presence of dispersants, using microballs, beads or sand. Processes involving hammer milling or the use of jaw, cone or gyratory crushers have also been used to comminute naturally-occurring calcium carbonate. Exemplary of such comminution processes are those disclosed in U.S. Pat. Nos. 3,989,195; 4,166,582; 4,278,208 and 4,325,514 and British Patent No. 1,482,258, all assigned to English Clays Lovering Pochin & Company Limited, and Canadian Patent No. 1,161,010, assigned to Pleuss-Stauffer.
It has now been discovered that certain finely divided, wet-ground, dispersant-free calcium carbonate pigment compositions in which the particle size distribution of calcium carbonate is within limits as set out in detail hereinbelow are particularly suitable for use in aqueous slurry or dry form as opacifying fillers for paper, and that when such pigment compositions are so used they provide a balance of filler retention, opacity, brightness and strength characteristics hitherto unobtainable using available ground calcium carbonate fillers, particularly those containing dispersants, and approaching or in some cases equalling that obtainable using typical precipitated calcium carbonate compositions. It has been discovered in particular that the omission of dispersant greatly enhances the filler retention of papers made using the novel calcium carbonate fillers of this invention. At the same time, these novel fillers increase opacity.
It is, therefore, an object of this invention to provide novel, aqueous or dried, finely divided calcium carbonate compositions.
It is also an object of this invention to provide novel, aqueous or dried, finely divided, wet-ground, dispersant-free calcium carbonate filler or pigment compositions.
A further object of this invention is to provide novel, aqueous or dried, finely divided, wet-ground, dispersant-free calcium carbonate filler or pigment compositions which, when used as fillers for paper, have a balance of filler retention, opacity, brightness and strength hitherto unobtainable using available ground calcium carbonate fillers, particularly those containing dispersants, and approaching or in some cases equalling that obtainable using typical precipitated calcium carbonate compositions.
These and other objects, as well as the nature, scope and utilization of the invention, will become readily apparent to those skilled in the art from the following description, the drawings and the appended claims.
SUMMARY OF THE INVENTION
This invention is based on the discovery that finely divided, wet-ground, dispersant-free calcium carbonate filler or pigment compositions in which the particles of calcium carbonate are distributed in particular amounts in a particular fashion--broadly stated: in fine particle size and narrow particle size distribution--are particularly suited for use in aqueous slurry or dry form as opacifying fillers for paper.
In particular, the particle size distribution in such calcium carbonate compositions must be such that:
1. The size in microns of the calcium carbonate particles at the 50% point ("D 50 ") on a SediGraph particle size distribution curve representing the composition, i.e., the point on the curve which represents the size at which 50% of the mass of all particles present in the composition is larger and 50% of the mass of all the particles present in the compositions is smaller, sometimes referred to as the mean particle size, must be no less than about 0.60 μm and no more than about 1.30 μm in equivalent spherical diameter. The SediGraph particle size analyzer is made by Micromeritics Instrument Corporation, Norcross, Ga. It measures settling rate to determine particle size distribution by application of Stokes Law.
2. The size in microns of the calcium carbonate particles at the 80% point ("D 80 ") on the SediGraph particle size distribution curve divided by the size in microns of the calcium carbonate particles at the 50% point on the curve, or "D 80 /D 50 ", must give a number not less than about 1.40 and no more than about 1.90. D 80 /D 50 is an indication of the breadth or slope of the particle size distribution curve. For example, a monodisperse sample would have a D 80 /D 50 =1.0. As the particle size distribution broadens, D 80 /D 50 will become larger.
3. The size in microns of the calcium carbonate particles at the 20% point ("D 20 ") on the SediGraph particle size distribution curve must be no less than about 0.30 μm and no more than about 0.80 μm in equivalent spherical diameter. D 20 is an estimate of the fines in the calcium carbonate composition.
In addition, the calcium carbonate particle size distribution in such compositions, as determined by SediGraph measurements, must be such that:
4. No more than about 2 weight percent of the particles present are larger than about 8 μm in equivalent spherical diameter.
5. At least about 98 weight percent of the particles present are less than about 8 μm in equivalent spherical diameter.
6. At least about 97 weight percent of the particles present are less than about 5 μm in equivalent spherical diameter.
7. At least about 90 weight percent of the particles present are less than about 3 μm in equivalent spherical diameter.
8. At least about 75 weight percent of the particles present are less than about 2 μm in equivalent spherical diameter.
9. At least about 35 weight percent of the particles present are less than about 1 μm in equivalent spherical diameter.
10. No more than about 25 weight percent of the particles present are less than about 0.4 μm in equivalent spherical diameter.
Particularly preferred calcium carbonate compositions falling within these limits include the following:
______________________________________D.sub.50, μm D.sub.80 /D.sub.50 D.sub.20, μm______________________________________about 0.92 about 1.74 about 0.4about 0.88 about 1.65 about 0.38______________________________________
wherein the calcium carbonate particle size distribution is such that:
No more than about 2 weight percent of the particles present are larger than about 8 μm in equivalent spherical diameter.
At least about 98 weight percent of the particles present are less than about 8 μm in equivalent spherical diameter.
At least about 97 weight percent of the particles present are less than about 5 μm in equivalent spherical diameter.
At least about 90 weight percent of the particles present are less than about 3μm in equivalent spherical diameter.
At least about 75 weight percent of the particles present are less than about 2 μm min equivalent spherical diameter.
At least about 40 weight percent of the particles present are less than about 1 μm in equivalent spherical diameter.
No more than about 10 weight percent of the particles present are less than about 0.2 μm in equivalent spherical diameter.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings,
FIG. 1 is a SediGraph particle size distribution curve representing the composition of Example I hereinbelow.
FIG. 2 is an electron micrograph (10,000×) taken to illustrate typical particles in the composition of Example I hereinbelow.
FIG. 3 is a SediGraph curve representing the composition of Example II herein below.
FIG. 4 is a SediGraph curve representing the composition of Comparative Example A hereinbelow.
DETAILED DESCRIPTION OF THE INVENTION
Among the naturally-occurring mineral species of calcium carbonate that can be used in practicing this invention are calcite, aragonite, mixtures of calcite and aragonite or other naturally-occurring minerals associated with aragonite, e.g., mixtures containing from about 5 weight percent to about 99 weight percent, based on the total weight of the mixture, of calcite, with all or substantially all of the remainder of the mixture being aragonite, dolomite, or minor amounts of impurity minerals such as quartz, chlorite, mica, feldspar, pyrite and the like. Chalk can be used in practicing this invention if suitably beneficiated and ground to the appropriate particle size distribution.
Methods of comminuting and classifying naturally-occurring calcium carbonate to provide finely ground materials having the particle size distributions called for by this invention are well known in the art. Exemplary of such methods are:
wet grinding in a ball mill;
wet grinding in a wet vertical media mill;
wet grinding in a wet horizontal media mill;
wet classification by means of a wet centrifugal classifier.
A comminuting and classifying sequence particularly useful in practicing this invention includes grinding in an autogenous mill (first coarse grinding), floating to remove impurities, fine wet grinding in a horizontal micromedia mill, and centrifugal wet classification to remove oversize particles and return them to the wet micromedia mill for further grinding.
The finely divided, wet-ground, dispersant-free calcium carbonate filler or pigment compositions of this invention may be shipped and stored as aqueous slurries containing from about 10% to about 60% by weight solids, or as filter cakes, centrifuge cakes or spray dried powders.
Such aqueous slurries, filter cakes, centrifuge cakes or spray dried powders can also contain minor amounts of flocculants, biocides, and like materials other than dispersants which are typically incorporated in filler or pigment slurries used in paper-making.
Dispersants are typically used in finely divided calcium carbonate-containing slurries to prevent the solids from flocculating and settling out. Dispersants also reduce the viscosity of such slurries, permitting them to flow and be pumped. This is advantageous from a materials handling standpoint and also reduces shipping costs. Dispersants, however, have an adverse effect on filler retention in papers made from calcium carbonate fillers containing them. For example, paper handsheets made under otherwise identical conditions--one group of such handsheets containing Supermite extra fine wet ground calcium carbonate filler produced by Cyprus-Thompson, Weinman and Company together with a dispersant and Kelzan rheology control agent (xanthan gum; Kelco Division of Merck & Co., Inc., Clark, N.J.), the other containing only the extra fine wet ground calcium carbonate filler--were found to differ significantly in filler retention. The sheets made with dispersant-containing filler retained only 37.7% of the filler; the sheets made with filler containing no dispersant retained 82.7% of the filler.
The adverse effect dispersants have on filler retention in turn affects opacity, since the smaller the amount of filler the paper retains the less opaque the paper will be. Adding dispersant to slurries of fillers then used to make paper handsheets under conditions otherwise identical to those used to make paper employing the same filler slurries, but without dispersant, was found to reduce the opacity of the handsheets made from the dispersant-containing slurries by from 1 to 2.5 percentage points, a very significant difference in opacity.
When making paper using aqueous slurries of the finely divided, wet-ground, dispersant-free calcium carbonate filler or pigment compositions of this invention, such slurries will be added to a slurry containing papermaking fibers after pulp disintegration (beating) and before the addition of any retention aid. The amount of aqueous calcium carbonate slurry added will be such that the finely divided calcium carbonate makes up from about 3% to about 30% by weight, on a dry basis, of the total solids in the furnish (filler plus fiber).
The procedure employed in making the handsheets referred to in the working examples hereinbelow was as follows:
Disintegration
1. 60.0 Grams of paper pulp on an oven dry basis were weighed out and divided into two 30 gram portions; each portion was diluted to 2000 ml and disintegrated in a standard TAPPI disintegrator at 3000 rpm for 5 minutes.
2. After disintegration the stock was poured into a 5 gallon bucket and diluted to 18 liters.
Addition of filler and chemicals
1. The pH of the stock was measured and, if necessary, adjusted to pH 7.5 with sodium hydroxide.
2. The weight of filler to be added to the pulp was calculated as follows: amount of filler to be added divided by percent filler added=60 grams oven dried (o.d.) pulp divided by o percent pulp, or: ##EQU1##
3. Filler slurries were added directly to pulp and mixed, for several minutes, with the weight being calculated on a dry basis.
4. Hercon 48 solution (cationic reactive size; Hercules Incorporated, Wilmington, Del.) was added to the pulp/filler slurry and mixed for 2 minutes.
5. The pH was adjusted to 8.5 with sodium hydroxide.
6. Fifteen aliquots of 0.1% retention aid solution were weighed for addition to the pulp just prior to handsheet formation.
Checksheet and Calculations
1. With the handsheet mold open the lower portion of the handsheet mold was filled with deionized water. The pH of the water was adjusted to pH 7.5 with sodium hydroxide or sulfuric acid.
2. The surface of the papermaking machine's wire was tapped to release any air bubbles trapped underneath. A clean 9 inch×9 inch screen was placed in the handsheet mold and the mold closed. The handsheet mold was then filled to within 2 inches from the top with deionized water controlled to proper pH. To 1000 ml of pulp furnish there was added the preweighed amount of 0.1% retention aid solution, and the resulting mixture was hand agitated. The 1000 ml of diluted stock was then poured into the handsheet mold.
3. The perforated stirrer was inserted into the mold and moved rapidly up and down five times, keeping the perforated plate beneath the surface of the liquid. On the last up stroke the stirrer was moved slowly and then gently withdrawn.
4. The valve to the white water recirculation tank was opened and the water was removed under vacuum.
5. Immediately after the water drained from the handsheet mold the pump was turned off, the drain valve was closed, the handsheet mold was opened, the screen and paper mat were removed, and the screen placed sheet side up between felts. After turning on the press motor, the felt blanket was placed between the press rolls and the handle pushed all the way down to bring the weights to bear on the rolls.
6. The checksheet was pressed twice to make it easier to remove from screen, then peeled from the screen and dried on a Noble and Wood Hot Plate (low heat setting) until completely dry. The sheet was weighed on a scale to 0.01 g, then the actual consistency of the pulp in the pail was calculated by dividing check sheet weight in grams by 1000 ml to give consistency in g/ml.
Sheet Making
1. The amount of pulp furnish necessary for the second sheet was calculated by dividing the actual weight of pulp/filler in the target sheet by the pulp consistency. Then, the desired sheet weight was divided by the consistency to determine the pulp required per sheet in milliliters.
Example:
2.50 g/1200 ml=0.00208 g/ml pulp consistency
3.28÷0.00208 g/ml pulp consistency=1580 ml pulp furnish.
2. Checksheet steps 1-6 were followed to make the first five filled sheets.
3. The amount of pulp furnish measured out for each sheet was adjusted if the filled sheet weight varied ±0.2 g from the target sheet weight.
4. Fifteen sheets were then made with the pulp and filler mixture. The first 5 sheets were thrown away, the purpose for making them being to increase the fines content of the white water to a point of equilibrium. Sheets 6-15 were saved for testing.
5. Steps 1-4 in making the checksheet were followed in making handsheets 6-15. After forming the handsheet the screen with the sheet up was placed on the felt blanket. The press motor was then turned on. With the leading edge of the felt between the rollers and the top felt folded back over the roller, a blotter was placed squarely on top of the sheet. The lever on the left side of the press was released and pushed all the way down to feed the felt, the screen, the sheet and the blotter through the press rolls.
After the sheet had been pressed, the press handle was raised to its initial position and the felt placed on the press table ready for the next sheet. The sheet and blotter were peeled together from the screen.
6. The sheets were then placed on a Noble and Wood Drum dryer with press blotter and sheet together, sheet side toward drum. The temperature of drum was approximately 200° F. When the sheets were dry to the touch, usually after 2 passes, the blotter was peeled from sheet, care being taken not to wrinkle the sheet. The sheet was then allowed to reach equilibrium moisture content for 24 hours prior to testing.
Handsheet Testing
1. Handsheets were tested for opacity, brightness, burst and tensile strength and sheet weight in accordance with TAPPI procedures. Filler contents and retention values were determined by low temperature ashing.
2. Optical tests were conducted on sheet numbers 9, 11 and 13, and physical tests on the even numbered sheets, unless one of these sheets was not uniform or had other defects, in which case one of the remaining sheets was used in its place. Tests were conducted in the following order: (1) Sheet weight, (2) Opacity, (3) Brightness, (4) Burst, (5) Caliper, (6) Tensile and (7) Paper ash. From this data scattering power, sheet scattering coefficient, pigment scattering coefficient, burst index, tensile index and filler retention were calculated.
The procedure employed in measuring particle size distribution with a SediGraph particle size analyzer, Model 5000D, in the working examples hereinbelow was as described immediately below. All quantities were calculated to add an amount of anionic dispersing agent equivalent to 2 lb./ton of this substance to aqueous slurries and 10 lb./ton to dry samples, so as to provide proper particle dispersion to permit accurate particle size distribution measurements.
I. SLURRY
Slurry Preparation
1. An amount of slurry sufficient to contain 3 grams of calcium carbonate was weighed into a 105 ml beaker with a stirring bar. ##EQU2## example: for a 72% solids slurry 300/72=4.17 grams of slurry were used
2. 10 Drops of 1% Colloid 230 solution (an anionic dispersing agent manufactured by North Chemical Co., Marietta, Ga.) were added to the beaker.
3. Deionized water was then added to the 100 ml mark on the beaker.
4. The beaker was then placed on the magnetic stirrer and stirred for 5 minutes.
5. The beaker was then covered with a 4"×4" square of Parafilm and approximately 12 holes were poked in the top.
6. The covered beaker was placed in an ultrasonic bath for 5 minutes, then degassed in a vacuum oven for 5 minutes.
7. Finally, the slurry was magnetically stirred for 2 minutes until ready for particle size determination.
Dry Sample Preparation
1. 3.00 Grams of sample were weighed onto a weighing paper.
2. The sample was transferred from the weighing paper into a 150 ml beaker, taking care to not spill any of the sample.
3. A stirring bar was placed in the beaker and about 50 ml of deionized water was added.
4. The beaker was placed on a magnetic stirrer and, while stirring, 1.5 ml of 1% Colloid 230 solution was added to the contents of the beaker. Note: Depending on the sample more or less Colloid 230 solution may be required to get proper dispersion.
5. Stirring was continued for 2 minutes, or until solid was well dispersed, the stirrer was shut off, and deionized water was added to the 100 ml mark on the beaker, and stirring was resumed for 5 minutes.
6. The beaker was then covered with a 4"×4" sheet of Parafilm and approximately 12 holes were poked in the top.
7. The covered beaker was placed in an ultra sonic bath for 5 minutes, then degassed in a vacuum oven for 5 minutes.
8. Finally, the slurry was magnetically stirred for 2 minutes until ready for particle size determination.
Particle Size Determination
1. The sample was placed in the sample compartment of the SediGraph 5000 D over the stirring mechanism and the stirrer speed turned up until the sample was turbulent enough to prevent settling.
2. The recorder was loaded with fully labeled graph paper according to the SediGraph manufacturer's instruction.
3. The "Run" switch was turned to "Reset" and then to its center "Off" position, and the 100 percent knob turned fully clockwise.
4. The approximate starting diameter was then set, stopping short of the desired starting diameter.
5. The recorder reference baseline (0 percent on the graph) was checked, using the "Zero" knob and "Zero" push button.
6. The cell was flushed and filled with clean liquid and the recorder baseline (0 percent on the graph) was set, using the 0 percent knob.
7. The dispersed sample was loaded into the sample cell.
8. The recorder was adjusted to 100 percent on the graph using the 100 percent knob, care being taken not to adjust below a setting of 500.
9. The exact starting diameter was set at 50 μm.
10. The temperature was then measured and the proper rate calculated.
11. The proper rate was switched in after measuring the temperature; 473 at 32°.
12. The cell was removed, inspected for bubbles, and replaced.
13. the starting diameter was rechecked and the recorder set to 100 percent on the graph paper.
14. The analysis was then started by switching the "Run" switch to "On".
15. The cell was then cleaned and flushed, leaving it filled with clean water.
16. The graph was removed and the analysis reported at the desired diameters.
EXAMPLE I
Limestone was ground in a 30 inch×42 inch jaw crusher to minus 31/2 in. particle size. This material was then screened to remove particles smaller than 1/2 inch.
The minus 31/2 inch, plus 1/2 inch stone was autogeneously wet ground at 30% solids in a 500 horsepower 7 foot diameter by 26 foot long tube mill to a particle size of 95 percent minus 200 mesh. This slurry was then treated with Alkazine T0 (imidazoline; Alkaryl Chemical Co.) an amine flotation reagent, in an amount of approximately 1/4 lb./ton of solids in the slurry (this amount can vary slightly depending on the amount and type of impurities present in the limestone starting material), and beneficiated by flotation to remove silica and silicate impurities.
Following flotation the slurry was passed through a Townley Hydroclone wet cyclone to remove particles larger than about 50 microns. The fines discharge from the cyclone was further classified in a 54 inch by 70 inch wet centrifugal classifier manufactured by Bird Machine Co. of South Walpole, Mass. to produce a slurry of particles having a mean particle size of 1.3 microns.
The slurry was transferred to a bowl thickener and 0.1 pound of Tamol 901, an anionic flocculating agent manufactured by Rohm & Haas Company, was added to the slurry for each ton of limestone to accelerate settling of the solids to a solids concentration of 41.7%.
A 3 gram sample, on a dry basis, of the settled solids was dispersed in water to give 100 ml of slurry, using 2 ml of 1% Colloid 230 solution, an anionic dispersing agent and the particle size distribution was measured with a SediGraph particle size analyzer, Model 5000D.
The SediGraph particle size distribution curve obtained for this composition is attached as FIG. 1. An electron micrograph (10,000×) of the particles in this composition is attached as FIG. 2.
The D 50 , D 80 /D 50 , D 20 and particle size distribution values for this calcium carbonate composition were found to be as follows: D 50 , 1.3 μm; D 80 /D 50 , 1.63; D 20 , 0.7 μm.
Particle size distribution
about 2 wt. % particles larger than about 4 μm
at least about 90 wt. % particles smaller than about 2.6 μm
at least about 75 wt. % particles smaller than about 2 μm
at least about 60 wt. % particles smaller than about 1.6 μm
at least about 50 wt. % particles smaller than about 1.3 μm
at least about 30 wt. % particles smaller than about 0.9 μm
about 20 wt.% particles smaller than about 0.7 μm
A portion of the thickened slurry was added to a slurry of bleached wood pulp consisting of 75% hardwood fibers and 25% softwood fibers refined to a Canadian Standard Freeness of 379 cc. The calcium carbonate slurry was added so that the final pulp plus slurry contained 20 pounds of calcium carbonate for each 80 pounds of oven dried wood pulp. To this slurry there was then added 2.5 pounds of Hercon 85 cationic sizing agent, manufactured by Hercules Chemical Co., Wilmington, Del., and 0.3 pounds of Reten 523 P anionic retention aid, also manufactured by Hercules, for each ton of total solids in the slurry. Paper was made from the resulting furnish on a Lou Calder pilot plant paper machine at Western Michigan University. The resulting paper is referred to herein as Paper A.
An identical papermaking procedure was followed in which the filler was a commercial anionically dispersed calcium carbonate slurry of essentially the same particle size distribution. The resulting paper is referred to herein as Paper B.
Papers A and B were analyzed for calcium carbonate content, from which filler retention was calculated, and measurements were made of the opacity and brightness of the paper sheets, from which sheet scattering coefficients and pigment scattering coefficients were calculated. The results obtained were as follows:
______________________________________ Sheet Pigment Scattering ScatteringRetention, % Opacity, % Coefficient Coefficient______________________________________Paper A 76.7 85.6 517 1707Paper B 48.9 82.1 432 1632______________________________________
Paper A, filled with a calcium carbonate composition prepared in accordance with this invention, retained much more of the filler and had a much higher opacity than paper B, filled with a commercial anionically dispersed calcium carbonate slurry. The opacity and sheet scattering coefficient of paper A would be expected to be higher than those of paper B because of the higher filler content of paper A. The higher pigment scattering coefficient of paper A, however, shows that the filler in this paper contributes higher opacity to the paper than does the commercially available anionically dispersed calcium carbonate filler when the differences in filler content are taken into consideration.
EXAMPLE II
A quantity of limestone was wet ground, purified by flotation, passed through a wet cyclone to remove oversize particles and classified in a centrifugal classifier in the manner set forth in Example I hereinabove. A portion of the fines discharged from the centrigual classifier was further classified in a second centrifugal classifier to produce a slurry of particles having a mean particle size (D 50 ) of 0.92 micron, a D 80 /D 50 ratio of 1.74, and a D 20 of 0.4 micron. The SediGraph particle size distribution curve obtained for this product is attached as FIG. 3. No flocculant was added to this slurry, which contained 10.6 percent solids.
A portion of this slurry was added to a slurry of bleached wood pulp consisting of 75% hardwood and 25% softwood fibers refined to a Canadian Standard Freeness of 350cc. The calcium-carbonate slurry was added in such a quantity that the final slurry contained 20 pounds of calcium carbonate for each 80 pounds of oven dried pulp. The same sizing and retention aid employed in Example I were added to this slurry in the same quantities as in Example I. This slurry was then made into 8×8 inch sheets of paper on a Noble and Wood Handsheet Machine with white water recirculation. The sheets were pressed on a Noble and Wood roll press with a felt blanket and dried on a Noble and Wood drum dryer, and then allowed to equilibrate with atmospheric moisture to a moisture content of 7-8%.
The thus-obtained sheets were analyzed for calcium carbonate content and their optical properties were measured. The resulting paper is referred to herein as Paper C.
The same procedure was followed to make paper handsheets in which the filler was a commercial anionically dispersed calcium carbonate slurry having a mean particle size (D 50 ) of 1.0 micron and a D 80 /D 50 ratio of 2.0. These sheets were analyzed in the manner described hereinabove for calcium carbonate content, and their optical properties were measured. The resulting paper is referred to herein as Paper D.
The properties measured for these two papers are shown in the table below:
______________________________________ Sheet Pigment Scattering ScatteringRetention, % Opacity, % Coefficient Coefficient______________________________________Paper C 92.0 90.4 598 1823Paper D 37.7 83.9 391 1362______________________________________
The paper filled with calcium carbonate prepared in accordance with this invention retained much more of the calcium carbonate than the paper filled with the commercial anionically dispersed calcium carbonate slurry. It also showed a much higher pigment scattering coefficient, demonstrating that calcium carbonate prepared in accordance with this invention has greatly superior filler properties in paper than does presently commercially available anionically dispersed ground calcium carbonate.
COMPARATIVE EXAMPLE A
A quantity of limestone was ground, purified by flotation and the oversize particles removed by centrifugal classification in the manner set forth in Example I hereinabove. A portion of the fines discharged from the centrifugal classifier was then further classified in a wet centrifugal classifier as set forth in Example II hereinabove, but the rotational speed of the classifier was reduced and the throughput rate was increased so that the particle size of the product was larger than those of the calcium carbonate slurry products of Examples I and II; D 50 =1.8, D 80 /D 50 =1.8.
Two sets of paper handsheets were made in the manner previously described above using this product as a filler. Analysis of the handsheets and testing of their optical properties resulted in the data in the following table. These handsheets are designated as Paper E and Paper F.
______________________________________ Pigment Scattering ScatteringRetention, % Opacity, % Coefficient Coefficient______________________________________Paper E 97.4 90.0 583 1668Paper F 99.4 88.5 565 1547______________________________________
From these data it can be seen that elimination of the dispersant resulted in very good retention of the filler in the paper. However, the pigment scattering coefficients are significantly lower than those of Papers A and C in Examples I and II, showing that the large mean particle size of the filler of this comparative example made it a less efficient opacifying agent than the fillers made in accordance with this invention.
The above discussion of this invention is directed primarily to preferred embodiments and practices thereof. It will be readily apparent to those skilled in the art that further changes and modifications in the actual implementation of the concepts described herein can readily be made without departing from the spirit and scope of the invention as defined by the following claims.
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Finely divided, wet-ground, dispersant-free calcium carbonate filler or pigment compositions are disclosed in which the particles of calcium carbonate are distributed in particular amounts in a particular fashion--broadly stated: in fine particle size distribution. Such compositions are useful in aqueous slurry or dry form as opacifying fillers for paper.
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This application is a continuation of application Ser. No. 438,300, filed Nov. 1, 1982, now abandoned.
FIELD OF THE INVENTION
This invention is concerned with improvements in or relating to fluid handling apparatus, such as heat exchanger apparatus and fluid reactor apparatus.
REVIEW OF THE PRIOR ART
It is of course a constant aim in all fields of manufacture to lower costs both of the apparatus itself and of its cost of operation and maintenance. In the case of heat exchange apparatus there is therefore a constant endeavour to improve efficiency, so that the cost of operation is reduced directly and so that the apparatus is smaller in size, which in itself is usually a desirable characteristic, such size reduction resulting in a requirement for less material in its fabrication. This reduction in material requirement is especially important in apparatus employed with corrosive fluids and in difficult environments when expensive corrosion-resistant materials must be used. It is also an endeavour to provide as great a freedom as possible from fouling, together with ease of assembly and disassembly, so as to give accompanying consequent economy in maintenance. There are similar advantages to be obtained in the case of fluid reaction apparatus, resulting from increases in efficiency of the fluid mixing and efficiency of contact with catalytic material, and also in the case of fluid reaction apparatus that has heat exchange capability to take account of the exothermic or endothermic nature of the reactions involved.
An improved heat exchange process and apparatus are disclosed in my prior European Patent application Ser. No. 81104809.9 (Publication No. 0 042 613) filed June 22, 1981, and published Dec. 30, 1981, the disclosure of which is incorporated herein by this reference. In this process and apparatus the fluid flow takes the form of a non-turbulent boundary layer or layers immediately adjacent to the heat transfer surface and a non-turbulent core layer interfacing with the boundary layer or layers. An interrupter structure is provided within the flow passage to interrupt is as non-turbulent a manner as possible the said boundary layer or layers at a plurality of spaced interruption spots, whereby parts of the interrupted boundary layer separate from the heat transfer surface and mix with the core layer to effect heat transfer between the surface and the core layer. This structure consists of densely-packed convex sphere segments each arranged with a part of its convex surface touching or almost touching the heat transfer surface. Such a structure provides a very high coefficient of heat transfer without a disproportionate increase in the pumping power required to move the fluid through the apparatus.
DEFINITION OF THE INVENTION
It is an object of the invention to provide a new fluid boundary layer interrupter structure for fluid handling apparatus.
In accordance with the present invention there is provided in a fluid handling apparatus an interrupter structure adapted for pointwise interruption of the boundary layer of a fluid flow over a surface or surfaces of the apparatus immediately adjacent to the interrupter structure, the said structure comprising:
a multiplicity of bladed interrupter elements disposed longitudinally relative to one another in the direction of flow of the fluid,
each bladed interrupter element comprising a common core and at least three blade-like members extending mutually outwardly from the common core so as to separately touch or nearly touch the said apparatus surface or surfaces immediately adjacent to the respective element, each blade-like member being of at least approximately spherical segment profile in side elevation, so that the portion thereof most closely adjacent to the respective apparatus surface protrudes into the said fluid flow boundary layer for pointwise interruption thereof;
each element thereby providing a number of adjacent pointwise boundary layer interruptions corresponding to the number of blade-like members thereof.
Also preferably the spacing between immediately successive interrupter elements is such as to produce wake interference flow in the fluid.
The fluid handling apparatus may comprise heat exchange apparatus in which the interrupter elements are disposed adjacent the surface of a wall through which heat exchange takes place.
The fluid handling apparatus may comprise a fluid reactor in which the interrupter structure is coated with a material exhibiting reactive and/or catalytic properties toward the fluid.
DESCRIPTION OF THE DRAWINGS
Fluid handling apparatus constituting preferred embodiments of the invention will now be described, by way of example, with reference to the accompanying diagrammatic drawings, wherein:
FIG. 1 is a longitudinal section through a heat exchanger embodying the invention, taken on the line 1--1 of FIG. 2, parts only of some of the tubes thereof being shown broken away and parts of structures being shown in phantom to avoid excessive detail;
FIG. 2 is a part transverse section through the apparatus of FIG. 1, taken on the line 2--2 of FIG. 1, only the lower right quadrant being shown in full to avoid excessive detail;
FIG. 3 is a transverse cross-section to an enlarged scale of an interrupter element of the apparatus of FIGS. 1 and 2;
FIGS. 4A, 4B and 4C are respective side elevations to an enlarged scale, and showing interrupter elements of different profiles;
FIG. 5 is a longitudinal cross-section through a single tube illustrating the fluid flow therethrough past an interrupter element;
FIG. 6 is a plot of ranking of different heat exchanger surfaces, including a surface/structure combination of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The heat exchanger of FIGS. 1 and 2 is of shell-and-tube type comprising a central shell member 10 having inlet 12 and outlet 14 for the fluid that is to pass in the shell around the outside of the tubes. The two ends of the shell member 10 are closed by two respective tube sheet assemblies, each consisting of two spaced tube sheets 16 and 18 through which pass the ends of a plurality of parallel tubes 20 so as to be supported by the tube sheets. The joints between the tubes and the apertures in the tube sheets through which they pass, and also the joints between the tube sheet assemblies and the adjacent shell members, are sealed by specially shaped unitary gaskets 22 and 24. Any of the two fluids that leak through the gaskets enters the space between the tube sheets and can be vented to atmosphere without cross-contamination of the fluids.
Two subsidiary like end members 26 and 28 are mounted on the respective ends of the central shell member 10 abutting the respective tube sheet assemblies to form respective plenums for the fluid that enters and discharges from the interiors of the tubes 20, and are provided respectively with inlet 30 and outlet 32 for such fluid. The ends of the shell end members 26 and 28 are closed by respective end plates 34 held to the members by respective encircling removable split rings 36 and tensioned band clamps 38. The tube sheet assemblies and the subsidiary members are held assembled with the central shell 10 in similar manner by means of encircling split rings 40 and tensioned band clamps 42, the split rings having radially inwardly extending projections that engage in respective circumferential grooves in the shell members.
Each tube 20 has mounted therein a respective fluid flow interrupter structure 44 of the invention comprising a multiplicity of longitudinally spaced interrupter elements 46, which in this embodiment are mounted longitudinally spaced from one another along the length of the tube on an elongated axial core element rod 48 of small diameter relative to the overall diameter of the elements. The ends of this rod are free of the interrupter elements and extend out of the tubes 20 through the respective plenums into contact with the adjacent faces of the removable end plates 34, so that the interrupter structures are maintained in fixed longitudinal positions in the tubes.
As is seen most clearly in FIGS. 2 and 3, each interrupter element 46 consists of a plurality of equal length blade like members 50 extending mutually radially outwards from the core rod 48 until they touch, or at least almost touch, the inside cylindrical wall of the respective tube. As is seen most clearly in FIGS. 1, 4, and 5 each blade like member is of convex curvilinear profile as seen in side elevation, so that it has only effectively a point 52 of its circumference in contact with the tube inner wall, or immediately adjacent thereto.
It is known to those skilled in the art that a fluid flowing within a passage, such as a tube 20, has a very thin virtually stationary boundary layer at the tube inner wall which insulates the wall surface from the main body of the fluid flowing in a core layer interfacing with the boundary layer, the boundary layer therefore reducing the heat transfer between the tube inner surface and the core layer. It is also known that an unobstructed boundary layer increases progressively in thickness in the direction of fluid flow, which will increase its insulating effect. Proposals have therefore been made hitherto to disrupt such boundary layers by roughening or ridging the surfaces over which they flow, but such proposals have the effect of also increasing to a disproportionately greater extent the pumping power required to move the fluid through the passage because of the turbulence that is generataed in the fluid.
In apparatus of the invention the boundary layer at the tube inner faces is interrupted in a "spot-wise" manner at circumferentially and longitudinally spaced spots by means of the fluid flow interrupter structure of the invention, while maintaining a non-turbulent fluid flow in the main body of the fluid constituted by the core layer. In the apparatus of the invention not only are the heat transfer surfaces not roughened, etc., but on the contrary they are made as smooth as is economically possible, to the extent that in some embodiments both the inner and the outer surfaces of the tubes 20 may be polished to the desired degree of smoothness. It will be seen that the blade-like members of each element intercept the boundary layer at a number of circumferentially-spaced spots surrounding the element corresponding to the number of members, and this occurs for each element of the structure along its length. The disruption of the boundary layer at the multitude of longitudinally and circumferentially spaced spots ensures that it stays thin, while the manner of its disruption ensures that turbulence is avoided that would cause unduly high friction drag.
It will be noted that the blade-like members of the interrupter elements are relatively thick at their root connections with the axial core rod and taper smoothly and progressively radially outwards until they terminate in a thin but smoothly rounded tip at or very closely adjacent to the tube inner surface. It will be understood by those skilled in the art that, because of usual manufacturing tolerances in the manufacture of the tubes and the interrupter structures, and also because of the need to be able easily to insert the structures into and remove them from the tubes, there may not always be positive contact at a particular interruption spot between the blade member and the tube interior wall, but the required effect will be obtained as long as the blade edge intrudes into the boundary layer. In a typical example of a small heat exchanger e.g. of capacity 20 liters/minute, and in which the tubes are of 1.25 cm internal diameter the tolerance required in the manufacture of the tube and interrupter structure is 0.5 mm to 1.0 mm, which is readily realisable.
At the radially inner part of each interrupter element, i.e. where the roots of the blades meet the core rod, there is a maximum of the ratio of blade surface area relative to the path cross-sectional area for fluid flow through the element, so that the friction drag is at a maximum. On the other hand, at the radially outer parts of the element blades the amount of blade material has become substantially zero, so that the friction drag is reduced in relation to the cross sectional area. Because of these differentials in friction and cross sectional area a change of momentum is produced in the fluid as it passes through the element that induces the development of smooth, non turbulent vortices producing rapid and effective mixing of the separated boundary layer and its adjacent core layer for increase in heat exchange efficiency. There is also highly effective contact of the fluid with the surface of the interrupter element and with any material such as a catalytic material thereon. The fluid in these momentum induced vortices moves from element to element longitudinally of the structure, and the spacing between the elements can be made such that what is known as wake interference flow is established by the coincidence between a vortex upstream of an interruption point with a vortex downstream of a subsequent interruption point; such wake interference flow is believed to provide the highest mixing and heat transfer efficiency with lowest required pumping power.
Another of the results of this particular blade configuration is that the fluid flow is predominantly in the radially outer portion of the tube interior with increased fluid velocities particularly at the tube inner wall surface. This type of flow has a number of beneficial effects on the heat transfer efficiency, in that the rate of heat transfer is fundamentally increased because of the rapid flow past the heat transfer surface, while the boundary layer is kept thin and more easily disrupted by the shearing effect of the high velocity fluid.
The general direction of flow of the fluid in a tube is indicated in FIG. 5 by arrows 54 and it will be seen that the flow interrupter structure causes the production of flow eddies of shape and rotational frequency that, as described above, depend upon the geometry of the structure. Wake eddies will be produced around the spots 52 of interruption downstream of the flow, while advance eddies will be produced upstream of the flow. If the spacing of the interruption spots 52 is made such that the advance and wake eddies of immediately successive spots coincide, then the desired wake interference flow is obtained with its very efficient non turbulent mixing between the interrupted boundary layers and the adjacent core layer. A turbulent flow, may be distinguished from a vortex of eddy in that the former is irregular and there is no observable pattern as with a vortex. Vortices, eddies and swirls therefore do not constitute turbulence. The conditions for maintenance of non turbulent flow with a particular structure can be observed for example by providing suitable windows in an experimental structure and adding visible fluids to the fluid flow if required.
The interrupter structure may readily be produced relatively inexpensively as a cast or moulded integral element of required diameter, element spacing and element free end length. A variety of different materials can be used, such as metals, non-metallic materials such as plastics materials, and refractory materials such as alumina and cements. Because of its relatively large surface area and its efficient surface contact with the mixing flowing fluid the interruption structure is particularly suited as a support for a layer of material with which the fluid is to be contacted, such as a catalytic material, as illustrated in broken lines by the reference 60 in FIG. 3. In other embodiments comprising reactor apparatus the interrupter structure itself can be made of the contact and/or catalytic material, and alumina is a specific example of such a material having this dual property.
The number of the blade like members to be provided with each interrupter element is a matter of design for each heat exchanger. A practical minimum is three, while for small exchangers (e.g. using tubes of 1.25 cm and less) more than ten would usually result in too great a loss of flow capacity.
FIG. 4a shows in side elevation part of a structure in which the profile of the element is spherical; the profile is of course a circle. Other profiles can be used and should be such as to present smoothly contoured edges to the fluid flow, so as to reduce friction losses to a minimum and also to ensure the maintenance of non turbulent flow. FIG. 4b shows for example elements of an ellipsoidal profile, while FIG. 4c shows elememts of an egg or drop shaped profile.; in the latter two profiles of the edge of largest radius faces upstream.
Special situations arise for example when the fluid is very viscous, such as a viscous oil that is to be heated. Such a fluid is usually of low thermal conductivity and a thermal boundary layer will be established immediately adjacent to the heat transfer surface that is much thinner than the flow boundary layer. The interrupting structure must be arranged to interrupt this thinner thermal boundary layer irrespective of the thickness of the flow boundary layer. The principal factor in the determination of the thickness of the thermal boundary layer is the Prandtl number, which is high when the viscosity is high and the thermal conductivity is low.
One of the principal parameters to be considered in determining whether a particular fluid flow will be non turbulent is the Reynolds number which is obtained by the relation: ##EQU1##
Classically it was believed that with a Reynolds number less than about 4,000 the flow must be non turbulent, while if it was greater than about 6,000 it would become turbulent. An indication that the flow will be non-turbulent is to plot a friction-factor curve, beginning at low Reynolds numbers, say R=100, which will show an abrupt change in slope at the onset of turbulence. The existence of a friction-factor curve of constant slope can therefore be an indication that essentially non-turbulent flow is occurring.
The evaluation of the performance of heat exchanger surfaces is a difficult subject because of the large number of variables involved, but one method that has gained acceptance is described in the Transactions of the Society of Mechanical Engineers, Vol. 100, August 1978 in a paper by J. G. Soland, W. M. Mack, Jr. and W. M. Rohsenow entitled "Performance Ranking of Plate-Fin Heat Exchanger Surfaces". This method involves the plotting of the number of heat transfer units (NTU) per unit volume of the heat exchanger core (V), against the pumping power (E) required to move the fluid through the core per unit volume of the heat exchanger core (V).
FIG. 7 is a plot of the ranking of surfaces in accordance with this method, comparing surfaces provided with an interrupter structure of the invention with a surface constituted by a tube of 1.2 cm diameter and a plate heat exchanger of 0.5 cm pitch. Thus the vertical plot indicates the number of heat transfer units (NTU) per unit volume of the heat exchanger core (V), while the horizontal plot indicates the pumping power (E) required to move the fluid through the core per unit volume of the heat exchanger core (V).
The test fluid was water and the lowest line A is for heat transfer in a plain tube of 1.2 cm diameter, using data obtained from the above-mentioned paper of Soland, Mack and Rohsenow. The line B is for an "APV" plate heat exchanger of 0.5 cm plate pitch, using data obtained from the "APV Heat Transfer Handbook, 2nd Edition, published by APV Inc. of Tonawanda, N.Y., U.S.A.". It will be seen that line B represents an improvement of 28% in performance over line A. A lower line C plots the performance of a shell and tube heat exchanger of the invention employing seven tubes of 1.25 cm diameter and equipped internally with radially bladed interrupter structures and externally with sphere rods on the shell side with a sphere diameter of 1 cm. The higher line D plots the maximum performance so far obtained with a heat exchanger of the invention. It will be seen that line C represents an improvement of respectively 250% and 200% of lines A and B, while line D represents an improvement of respectively 515% and 400%.
The embodiment of FIGS. 1 to 3 employs a different form of interrupter structure in the fluid path constituted by the space between the shell interior and the tube exteriors, although the above described bladed structure can of course be used. This different structure also consists of a core rod 54, but the longitudinally spaced interrupter elements consist of solid spheres 56 mounted on the rod at the spacing required to provide wake interference fluid flow. These sphere carrying rods, for convenience called sphere rods, are disposed around the tube exteriors with their longitudinal axes parallel to the tube axes and with their spherical surfaces in point contact with the adjacent tube surfaces; at some locations the spheres may also touch one another. The spheres have the same effect of point interruption of the boundary layers and production of mixing vortices that increase the heat transfer from the exterior tube surfaces to the fluid. It will be noted that the ends of the sphere rod cores are free of spheres and are in end engagement with the tube sheets 16, so that they can be located accurately longitudinally; by changing the length of the sphere free ends the spheres of one rod can therefore be arranged to be opposite to the spaces between the spheres on the immediately adjacent rods to ensure the maximum flow flow capacity in the path, and minimize the pressure drop of the fluid through the shell. The rod ends are also made free of spheres to provide fluid flow plenum spaces of adequate flow capacity in the shell adjacent the inlet and outlet to the shell. The radially outer sides of the radially outermost sphere rods are surrounded by a filler material 58 to block the non heat exchanging flow of fluid that would otherwise take place between the inner wall of the shell and the adjacent outer parts of the tube walls.
It will be seen that the entire heat exchanger is readily disassembled by removal of the encircling band clamps 38 and 42 and split rings 36 and 40, when the tube sheet assemblies can be removed and the interrupter assemblies of both types slid out from inside and between the tubes for replacement or cleaning, as may be required. It will be seen that this disassembly and subsequent reassembly can be effected extremely rapidly by unskilled labour using simple tools. The resulting separate parts can easily be cleaned with simple apparatus.
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The invention provides fluid handling apparatus which may be heat exchange apparatus or fluid reaction apparatus. The apparatus is provided with an interrupter structure for disrupting the fluid boundary layers at the walls of the apparatus and promoting mixing of the separated boundary layers with the adjacent core layers. One interrupter structure comprises a plurality of longitudinally-spaced interrupter elements mounted on a core rod, each element comprising a plurality of blade-like members each of at least approximately spherical segment profile in side elevation, the members extending mutually radially outward relative to one another to touch or nearly touch the said surface or surfaces adjacent the elements. The elements are spaced longitudinally from one another the distance required to provide wake interference flow of the fluid, wherein the vortex upstream of one element cooperates with the vortex downstream of the next element in the fluid path. In a shell and tube type exchanger the bladed type of structure may be provided in the tubes interiors, while a spherical type of interrupter structure is provided in the shell contacting the tube exteriors.
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FIELD OF THE INVENTION
This invention relates to outer soles that are worn by persons over regular footwear. In one format it relates to an outer-sole for persons who wish to minimize the risks of slipping on ice and snow. More particularly, it relates to a method of manufacture and outer-sole product that performs the above function in a superior manner.
BACKGROUND OF THE INVENTION
It has been known for sometime to design anti-slip outer soles that are provided with cleats. This has been generally been done in the form of sandals or some type of clip-on device that is attached beneath the sole portion of regular footwear.
Examples of such an item include the following Canadian patents:
CA: 175,047 to Kirkwood Feb. 19, 1917. 223,887 to Roe Sep. 19, 1922. 301,313 to Chase Jun. 17, 1930. 398,787 to Lawson Aug. 26, 1941. 527,399 to Smith Jul. 10, 1956. 549,159 to Griffin Nov. 20, 1956. 650,756 to Bailey Oct. 23, 1962. 669,630 to Smith Sep. 3, 1963. 781,673 to Vogt Apr. 2, 1968.
All of the foregoing references rely upon either full-sole outer soles, or partial-sole attachments, provided in either case with means for attachment to a regular boot or shoe.
Customarily such attachments are by means of straps. In other cases the attachment means employs toe and/or heel embracing hoods or caps. Where straps are employed, the outer soles are customarily of the sandal-type, wherein the sole is generally planar, and the toe and heel of the wearer's boot are exposed.
The present invention concerns a full-sole outer sole. Such an item of footwear should be light and durable. It should remain firmly in position during use, while being sufficiently pliable to permit a wearer to walk comfortably, in the normal way. These features are present in a sandal-type outer sole that is made from a flexible, resilient material such as rubber.
A problem arises, however, when a thin sandal-type format is adopted for such outer soles. Because the sandal-type sole is preferably thin (to enhance flexibility and reduce weight) and is not attached to the toe or heel of the principal boot by a hood or cap, the sandal-type sole does not readily lie against the wearer's boot. Instead small gaps open, both at the heel and toe while walking.
A problem associated with such gaps is that they tend to collect snow or dirt. This is particularly true at the toe, due to the forward motion of the foot, and the inclined angle of the foot just as it is being picked up to be swung forward.
The accumulation of snow between the outer sole and the boot is irritating for the wearer. Once snow has so accumulated, the foot no longer lies in its natural orientation during walking. Under pressure the accumulated snow may give-way, causing a momentary loss, or irregularity, of support for the wearer's foot. At minimum, this is an anxiety-creating event.
The present invention is directed to providing an outer sole of the sandal-type, for use over pre-existing footwear or boots, that is adapted to minimize the accumulation of snow or dirt between the toe of the boot and the front-end of the outer sole. Provision is also made for the accumulation of snow or dirt at the heel to be minimized. Optionally, such outer soles may be cleated to improve their traction on ice.
The invention in its general form will first be described, and then its implementation in the form of specific embodiments will be detailed with reference to the drawings following hereafter. These embodiments are intended to demonstrate the principle of the invention, and the manner of its implementation. The invention will then be further described, and defined, in each of the individual claims which conclude this specification.
SUMMARY OF THE INVENTION
The invention consists of an outer sole for wearing over footwear having toe and heel portions, such outer-sole comprising:
(1) a generally planar flexible lower tread portion having corresponding toe and heel portions to said footwear;
(2) an elastically extensible, generally planar, upper footwear-contacting portion bonded to the upper surface of the tread portion;
(3) attachment means, which may be in the form of straps, for attaching the outer sole to the lower surface of the aforesaid footwear,
wherein the said upper portion is elastically extended in the toe region of the tread portion of the outer sole to thereby cause the toe region of the tread portion to be curled upwards in the absence of said footwear, and to press against the toe portion of the footwear when the outer sole is attached thereto.
"Planar" as used above, and throughout this patent Specification, means that the tread and upper portions are are relatively thin in comparison with their longitudinal and lateral dimensions, being predominantly two dimensional and capable of being aligned with a plane, although they need not always be so aligned.
By a further feature of the invention, the upper portion of the outer sole may be elastically extended in the heel region of the tread portion of the outer sole to thereby cause such heel region to be curled upwards in the absence of the footwear, and to press against the heel portion of the footwear when the outer sole is attached thereto.
To provide lateral bending rigidity to the outer sole in combination with lateral support, the lower surface of the lower portion may be provided with a series of transverse, protruding ridges, which may optionally rise in height as proceeding from the lateral edges of the outer soles to a maximum height at about to the longitudinal center line of the outer soles. Such ridges should accommodate the ready flexing of the outer sole along lines transverse to its length. This is accomplished by separating such ridges by inter-ridge spacing that extend fully across the width of the outer sole.
These ridges may be provided in combination with a series of elevated posts, distributed along both sides of said outer sole proximate to its lateral edges, such posts protruding to a height which is substantially the same as the maximum height of the most proximate ridge. In this manner a tread may be provided to improve traction on soft surfaces; and provision made to receive metal studs on the ends of the elevated posts to improve traction on ice.
By a further feature of the invention, said posts may be provided with studs in the form of self-tapping metal screws that are affixed to the ends of such studs.
By reason of the curled feature of this outer-sole as described, a means is provided for avoiding the deficiencies recited above in the introduction.
The foregoing summarizes the principal features of the invention. The invention may be further understood by the description of the preferred embodiments, in conjunction with the drawings, which now follow.
SUMMARY OF THE FIGURES
FIG. 1 is a side view of a boot with an outer sole made in accordance with the invention attached thereto;
FIG. 2 is a plan view of the outer sole, viewed from the tread side, and with the attachment straps spread out;
FIG. 3 is an exploded side view of the lower tread portion of the outer sole with the upper portion above, shown before attachment without straps attached and with a single sample stud installed;
FIG. 4 is a side view of the complete outer-sole standing alone, unattached to footwear and the straps removed; and
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 a boot 1 is shown attached by straps 2 to an outer-sole 3. The outer sole 3 has metal studs 4 attached to posts 5 descending from the lower tread portion 6 of the outer sole. An upper portion 7 lies bonded to the tread portion, suitably by glue, sonic welding or the equivalent. Upwardly-curled toe 8 and heel 9 portions of the outer-sole 3 lie in contact with the toe 10 and heel 11 regions of the boot.
In FIG. 2 the tread portion 6 of the outer-sole 3 is shown to have transverse ridges 12 which are, in this example, chevron-shaped. Any other shapes adapted to provide traction on soft-soil will be suitable, the chevron format being known to release mud and snow readily. Such ridges 12 are separated by inter-ridge gaps 13 that extend across the entire width of the outer-soles 3 and allow the outer-sole 3 to flex.
Posts 5 carry metal studs 4 which may conveniently be self-tapping metal screws. The height of each post 5 is substantially the same as the maximum height of the most proximate ridge 12.
In FIG. 3 the upper 7 and lower 6 portions of the outer-sole 3 are shown before assembly. The upper portion 7 may be made of a thin rubber sheet or equivalent, textured on its upper surface 16 to better engage the lower sole surface of the boot 1.
The upper portion 7, which may be of 3 mm thickness, is shown as being slightly shorter than the lower portion 6. This is to allow for stretching during the manufacturing process. On a sole of overall length of 23 cm, it has been found satisfactory for the upper portion 7 to be shortened by about 1/2 cm at each end.
In assembling the upper and lower portions 7, 6 the central region 14 is first bonded to the tread portion, conveniently by contact cement. On a 23 cm sole this central region may extend over 10-14 cm.
After this initial bonding has set, the upper portion 7 is stretched in the toe and heel regions and then glued, as by contact cement, to the toe and heel portions 8, 9 of the outer sole 3. This causes the toe and heel portions 8, 9 to curl upwards, and this configuration is allowed to remain until the bonding sets. The upper and lower portions 7, 6 are then stitched together by stitching 15, around their outer margins.
As can be seen in FIG. 1, the effect of the curled portions is to press the toe and heel portions 8, 9 of the outer sole 3 against the lower sole of the boot 1, in the vicinity of its toe and heel regions 10, 11.
It has been found that the combined strengths of the materials and degree of stretching in the upper portion 6 should produce an up-turn, at the toe and heel, to an angle of about 55 degrees + 5 degrees.
The foregoing has constituted a description of specific embodiments showing how the invention may be applied and put into use. These embodiments are only exemplary, The invention in its broadest, and more specific aspects, is further described and defined in the claims which now follow.
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An outer-sole to be worn over footwear is characterized by having a curled forward or toe portion, and optionally heel portion as well, that holds the front portion of the outer-sole in contact with the footwear to which it is attached.
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RELATED APPLICATIONS
[0001] This application is a continuation of application Ser. No. 14/594,407 filed on Jan. 12, 2015. application Ser. No. 14/594,407 is a continuation in part of application Ser. No. 13/663,756, filed on Oct. 30, 2012, now U.S. Pat. No. 9,956,077. application Ser. No. 13/663,756 claims the benefit of U.S. Provisional Application No. 61/553,403, filed Oct. 31, 2011. All of these applications are herein incorporated by reference in their entirety for all purposes.
FIELD OF THE INVENTION
[0002] The invention relates to temporary barriers, such as dikes used for flood control, and more particularly, to water-filled portable barriers.
BACKGROUND OF THE INVENTION
[0003] Circumstances sometimes arise where a temporary dike, wall, or other barrier is needed to prevent a flood, landslide, or other threat from spreading and threatening lives and property. Often, such a temporary barrier is constructed from sandbags, whereby empty bags and a quantity of dirt or sand is brought to the site, and a crew of workers fills the bags with the dirt or sand and stacks the bags to form the barrier. With reference to FIG. 1 , the bags are often stacked so as to form a barrier with a “pyramid” cross-section 100 that is widest at the base, and narrower at the top.
[0004] In some cases, the barrier 100 is constructed on flat ground, and the weight of the sand in the barrier 100 is sufficient to hold the barrier 100 in place during the flood or other threat. With reference to FIG. 2 , in other cases a shallow trench 200 is prepared first, the trench having a depth that is approximately equal to the thickness of one sandbag. One or two rows of sandbags 202 are laid in the trench 200 , with the remainder of the barrier 100 being constructed on top of the initial one or two rows 202 . In this way, friction between the sandbags in the trench and the remainder of the sandbags further helps to hold the barrier in place.
[0005] While a sandbag barrier is generally effective and the materials are relatively inexpensive, there can be significant costs and construction time associated with a sandbag dike, due to the requirement to bring the sand or dirt to the construction site, which may weigh many tons, and due to the need to employ significant labor to fill and stack the bags.
[0006] In addition, after the flood or other threat has subsided, disposal of the sandbags can be time consuming and costly, especially if the sand and bags have become wet and contaminated by flood water and require special disposal procedures to avoid risks to health and to the environment.
[0007] What is needed, therefore, is a portable dike, wall, or other barrier that functions in a manner similar to a sandbag dike or wall, but does not require delivery of large quantities of heavy materials to the construction site, does not require large amounts of labor to assemble, and is simple and inexpensive to remove when it is no longer needed.
SUMMARY OF THE INVENTION
[0008] A portable, water-inflatable barrier has an internal structure similar to a sandbag dike or wall, and functions in a similar manner, but does not require delivery of large quantities of heavy materials to the construction site, does not require large amounts of labor to assemble, and is simple and inexpensive to remove when no longer needed. The barrier is made of a light, flexible material such as a heavy plastic or nanofiber, and can be transported to the construction site in a deflated state, after which it is positioned and filled with locally available water.
[0009] In one general aspect of the present invention, the barrier is a single unit that includes shaping and internal partitions which create an overall structure similar to a sandbag wall. The interior of the barrier is divided into a plurality of approximately rectangular cells. Passages between the tops and bottoms of the cells allow the entire barrier to be filled from a single water inlet. In some embodiments, the cells include passive automatic valves that seal the passages after the cells are filled with water, so that deflation of one cell due to a puncture or some other cause will not cause the cells beneath it to deflate. In some embodiments, the outer shell of the barrier is made of a thicker material, such as thick plastic, a synthetic rubber, or a thick layer of nanofiber, so as to better resist puncture by an external threat. In similar embodiments, the outer shell is double-walled, so that puncture of the outer wall does not affect the internal cells, so long as the inner wall remains intact. In certain embodiments the walls are coated with a protective material such as tyvec or liquid rubber that will seal punctures if they occur.
[0010] The unitary nature of the barrier in these embodiments eliminates any concern about interlocking and potential separation of individual units. The internal structure of the barrier enables it to maintain its shape when the barrier is subjected to externally applied horizontal forces, such as pressure from flood waters. In some embodiments, the shape of the structure is made even more rigid by the inclusion within the cells of stiff, lightweight rods or plates made of plastic, bamboo, or a similar material.
[0011] In further embodiments, additional rows of cells extend below the base of the inflatable barrier so that they can be placed in a trench prepared at the construction site; thereby further resisting dislodgement of the barrier by flood waters or other forces.
[0012] In some embodiments, the barrier can be initially inflated with air, so that the barrier can be easily positioned while it is in its filled configuration. The barrier can then be filled with water, while the displaced air is released through a pressure valve at the top of the barrier.
[0013] In circumstances where a long dyke or other barrier is required, a plurality of barriers of the present invention can be placed side-by-side. In some embodiments, the barriers have interlocking ends that provide structural cooperation and a water-tight seal between adjacent barriers. In some of these embodiments, pre-inflation of the barriers with air allows them to be easily placed in their interlocking configuration before the air within the barriers is replaced by water.
[0014] In a second general aspect of the present invention, the barrier is assembled from individual, water-inflatable modules that interconnect with each other, by ties, hook-and-loop, or by any other attachment mechanism known in the art. In some of these embodiments, the individual modules are triangular or wedge-shaped in cross section, thereby allowing the modules to be assembled so as to create an overall shape that is optimal for a specific circumstance.
[0015] Embodiments of the present invention include an anchoring sheet that surrounds part or all of the barrier, or is otherwise attached to the barrier, and extends flat against the ground in front of the barrier, so that the weight of the water in front of the barrier presses the anchoring sheet against the ground and creates a high frictional resistance to movement, thereby anchoring the barrier in place. In some embodiments, the anchoring sheet covers a water-facing surface of the barrier, and is sufficiently flexible to allow it to conform closely with the underlying shape of the water-facing surface. And in some of these embodiments, the anchoring sheet is made from a material that naturally clings to the water-facing surface of the barrier due to static electrical attraction.
[0016] Other embodiments include a flexible underlying sheet that further resists puncture from beneath, and which seals to the ground so as to resist penetration of water beneath the barrier. In some of these embodiments, the underlying sheet includes a cushioning layer. In other of these embodiments, the underlying sheet is filled with dry sand, foam or some other compliant material that will not get wet from the flood water.
[0017] In some embodiments, a base width of the barrier is at least six times as large as a height of the barrier.
[0018] Some embodiments include a ladder that is configured to be free-standing, but to conform somewhat closely to the outer profile of the barrier. The ladder allows for a convenient means for crossing the barrier, and provides additional structural support to the barrier by inhibiting distortion of the shape of the barrier. In embodiments, the ladder further provides horizontal and/or vertical support to the barrier by including coupling features on the ladder that can be attached to complementary coupling features provided on the top of the barrier.
[0019] The present invention is a water inflatable module suitable for use as a barrier or incorporation into a barrier. The module includes flexible walls configured to contain water within an interior of the module, said module having a front, a rear, a length parallel to the front, a width perpendicular to the front, and a substantially uniform cross-section along its length, the cross section being wider at a base of the module than at a top of the module. The module further includes a plurality of substantially horizontal and substantially vertical partition walls dividing said interior into a plurality of adjacent, water-tight cells shaped as rectangular parallelepipeds, front and rear partition walls of each cell being substantially parallel to the front of the shell, said cells being arranged in a plurality of vertically stacked layers that are offset from each other such that none of the front and rear partition walls aligns with a front or rear partition wall in a vertically adjacent layer. In addition, the module includes a water inlet, and a plurality of passages between the cells configured to allow filling of all of the cells with water from the water inlet.
[0020] Embodiments further include a structure reinforcing element that is external to the flexible walls.
[0021] Certain embodiments further include a rigid ladder spanning the width of the flexible walls in substantial conformance with a step-wise cross-sectional shape of the flexible walls, the ladder being configured to enable an individual to traverse the flexible walls. Some of these embodiments further include a first coupling mechanism attached to the ladder and a second coupling mechanism attached to the flexible walls, the coupling mechanisms being configured for attachment of the ladder to the flexible walls. And some in some of these embodiments the coupling mechanisms are configured to enable the ladder to provide vertical support to the flexible walls.
[0022] Some embodiments further include an automatic valve cooperative with a vertical passage between adjacent cells and configured to automatically seal the vertical passage when the cell below the vertical passage is filled with water.
[0023] Some embodiments further include an automatic valve cooperative with a horizontal passage between adjacent cells and configured to automatically seal the horizontal passage when the cell located to the rear of the horizontal opening is filled with water.
[0024] Embodiments include an interlocking side structure configured to interlock with a second module having a compatible side structure. In some embodiments the module is inflatable with air.
[0025] In some embodiments the base of the module is flat. In other embodiments, the base of the module includes at least one row of cells extending below other rows in the base, the extended rows being configured for placement in a trench prepared at a site where the module is to be installed.
[0026] In embodiments, the flexible walls are reinforced at least at the front of the module as compared to the partition walls. In some of these embodiments the flexible walls at the front of the module are reinforced due to an increased thickness of material relative to the partition walls. In other of these embodiments the flexible walls at the front of the module are reinforced due to inclusion of a material not included in the partition walls. In still other of these embodiments the flexible walls at the front of the module are reinforced due to inclusion of nanofiber in the flexible walls. In yet other of these embodiments the flexible walls at the front of the module are reinforced due to double-walled construction.
[0027] In some embodiments, the flexible walls include a coating of a protective material that tends to seal punctures. In some of these embodiments the protective material is tyvec or liquid rubber.
[0028] Certain embodiments further include an underlying sheet that resists puncture of the flexible walls from beneath, and which seals to the module and to the ground beneath the module so as to inhibit penetration of water beneath the module. In some of these embodiments, the underlying sheet is a cushioning layer. And in other of these embodiments the underlying sheet is filled with dry sand or foam.
[0029] And some embodiments further include a plurality of said modules aligned with adjacent sides so as to collectively form a water barrier, damn, or dyke.
[0030] The features and advantages described herein are not all-inclusive and, in particular, many additional features and advantages will be apparent to one of ordinary skill in the art in view of the drawings, specification, and claims. Moreover, it should be noted that the language used in the specification has been principally selected for readability and instructional purposes, and not to limit the scope of the inventive subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] FIG. 1 is perspective view of a sandbag barrier of the prior art having a flat base;
[0032] FIG. 2 is perspective view of a sandbag barrier of the prior art having two rows of sandbags at its base that are placed in a trench prepared at the construction site;
[0033] FIG. 3 is a perspective view of an embodiment of the present invention;
[0034] FIG. 4A is a cross sectional view of an embodiment having a water inlet on top, a water outlet near the bottom, and simple passages between tops and bottoms of cells;
[0035] FIG. 4B is a cross sectional view of an embodiment similar to FIG. 4A , but including only a water port at the top through which the barrier is both filled and emptied with water;
[0036] FIG. 5 is a partial cross sectional view of an embodiment having passages between tops and bottoms of cells that are closable by passive valves;
[0037] FIG. 6 is a cross sectional view of an embodiment that includes stiffening rods within the cells;
[0038] FIG. 7 is a perspective view of an embodiment that has two additional rows of cells at its base that are placed in a trench prepared at the construction site;
[0039] FIG. 8 is a perspective view of an embodiment that has interlocking ends;
[0040] FIG. 9A is a perspective view of an individual, inflatable module having a triangular cross section that can be combined with similar modules to form a barrier in embodiments of the present invention;
[0041] FIG. 9B is a cross-sectional view of a barrier constructed using the modules of FIG. 9A , and further including an anchoring sheet and an underlying sheet;
[0042] FIG. 10 is a perspective view of an embodiment of the present invention which includes a ladder that provides a means for crossing the barrier and also provides vertical support to the barrier;
[0043] FIG. 11 is a cross-sectional view of the embodiment of FIG. 10 ;
[0044] FIG. 12 is a close-up view of the top of FIG. 11 ; and
[0045] FIG. 13 is a cross-sectional view of an embodiment similar to FIG. 11 , but wherein the ladder does not provide vertical support to the barrier, but is optimized to inhibit distortion of the shape of the barrier.
DETAILED DESCRIPTION
[0046] With reference to FIG. 3 , the present invention is a portable, water-inflatable barrier 300 that has a structure similar to a sandbag dike or wall 100 and functions in a similar manner, but does not require delivery of large quantities of heavy materials to the construction site, does not require large amounts of labor to assemble, and is simple and inexpensive to remove when no longer needed. The barrier 300 is made of a light, flexible material, such as a heavy plastic for nanofiber, and can be transported to the construction site in a deflated state, after which it is positioned and filled with locally available water. In embodiments, the barrier material is coated with a material such as tyvec or liquid rubber that will tend to seal any puncture of the material that may occur.
[0047] FIG. 3 illustrates an embodiment of a first general aspect of the present invention in which the barrier is a single unit 300 that includes shaping and internal partitions which create an overall structure similar to a sandbag wall. The interior of the barrier is divided into a plurality of approximately rectangular cells 302 . With reference to FIG. 4A , passages 400 between the tops and bottoms of the cells 302 allow the entire barrier 300 to be filled from a single water inlet 402 . A separate water outlet 404 is provided at the base of the structure 300 .
[0048] With reference to FIG. 4B , in some embodiments a separate water outlet 404 is not included, and instead water is both added and removed through a common port 406 at or near the top of the barrier. This allows water to be removed from the barrier without introducing air, so that removing the water causes the barrier to be collapsed in preparation for packing and transport.
[0049] In some embodiments, lateral passages (not shown) are provided at least between adjoining cells in the bottom rear row, so that a single outlet can drain all of the cells 302 in the barrier 300 .
[0050] With reference to FIG. 5 , in some embodiments 500 the cells 302 include passive automatic valves 500 that seal the passages 400 after the cells 302 are filled with water, so that deflation of one cell due to a puncture or some other cause will not cause the cells beneath it to deflate. In the embodiment 500 of FIG. 5 , the valves 502 are flaps of elastic material joined to the upper surfaces of the cells 302 by living hinges 504 . A small air bladder 506 is included in the region of the valve 502 that is positioned to cover the passage 400 . When the cell 302 is empty, gravity causes the valve 502 to fall away from the passage 400 , so that the cell 302 can fill with water. However, once the cell 302 is full of water, the air bladder 506 lifts the valve 502 into place and closes the passage 400 . Once the valves 502 are closed, if a cell should develop a leak and deflate, only the cells directly above it will be affected.
[0051] In addition, the embodiment 500 of FIG. 5 includes lateral passages 508 between neighboring cells at the lowest level of the barrier, so that the entire barrier can be emptied through a single water outlet 404 located at the lower rear of the structure 500 . These lateral passages 508 include automatic valves 510 that will allow water to flow toward the rear as the cells empty from back to front, but will prevent water flowing from rear to front if one of the front cells is damaged.
[0052] Typically, the cells in the front row 302 , 302 A will be the cells that are directly exposed to threats such as debris carried by flood waters. The front cells 302 , 302 A are therefore the ones most likely to be damaged or punctured. In the embodiment of FIG. 5 , if a cell 302 A in the bottom front row is punctured, the lateral valve 510 will prevent water from flowing out of the cell next to it 302 B and into the damaged cell 302 A. However, if the rear cells 302 B are drained first during the normal drainage process, then the lateral valves 510 will open and water from the front cells 302 A will flow out.
[0053] With reference to FIG. 6 , in some embodiments the outer shell is made of a much thicker material than the internal cell walls 608 , so as to better resist puncture by exterior threats. In similar embodiments, the outer shell 606 is a double layer of material, so that penetration of the outer layer does not affect the adjacent cell, so long as the inner layer remains intact. In some embodiments, only the portion of the outer shell 606 that will face the flood or other threat is thicker, double-walled, or otherwise reinforced.
[0054] In embodiments, the internal cell walls enable the barrier 300 to maintain its shape when it is subjected to externally applied lateral forces, such as pressure from flood waters. As illustrated in FIG. 6 , in some embodiments, the shape of the barrier 600 is made even more rigid by including within the cells 302 stiff, lightweight rods 602 or panels made of plastic, bamboo, or a similar material.
[0055] In certain embodiments, the shape of the barrier is supported by external reinforcing structures. The embodiment of FIG. 608 includes a plurality of bent metal rods 608 that can be located at intervals along the rear side of the barrier 600 . The rods 608 include vertical sections 610 that can be placed against the back sides of cells at the rear of the barrier 600 so as to provide further resistance to horizontal forces applied to the front of the barrier.
[0056] In some embodiments, the barrier 600 can be initially inflated with air, so that the barrier 600 can be easily positioned while it is in its inflated configuration. The barrier 600 can then be filled with water, while the displaced air is released through a pressure valve 604 at the top of the barrier 600 .
[0057] With reference to FIG. 7 , in further embodiments, additional rows 702 of cells extend below the base of the inflatable barrier 700 so that they can be placed in a trench 200 prepared at the construction site, thereby further resisting dislodgement of the barrier 700 by flood waters or other forces.
[0058] In circumstances where a long wall or dike is required, a plurality of barriers of the present invention can be placed side-by-side. With reference to FIG. 8 , in some embodiments the barriers 800 have interlocking ends that provide structural cooperation and a water-tight seal between adjacent barriers. In the embodiment of FIG. 8 , alternate rows of cells 802 extend from the end by a length of one cell, while the interleaved rows 804 do not. The opposite pattern is provided on the other end of the barrier 800 . It can be seen that a second barrier of the same configuration can be positioned so that its extended cells fit between the extended cells 802 of the adjacent barrier 800 . In some of these embodiments, as mentioned above, the barrier 800 can be initially filled with air, and then positioned with the ends interlocking, after which the barriers are filled with water while the displaced air is allowed to escape through pressure valves provided at the tops of the barriers 800 .
[0059] With reference to FIGS. 9A and 9B , in a second general aspect of the present invention the barrier is assembled from individual, water-inflatable modules 900 that include attachment mechanisms 902 such as ties, hook-and-loop, or some other attachment mechanism known in the art. In the embodiment of FIGS. 9A and 9B , the modules have a triangular cross-sectional shape. As illustrated in FIG. 9B , this enables them to be assembled to form a barrier having a desired overall shape, such as a pyramid. While the base of the barrier is only slightly wider than the height in FIG. 9B , in other embodiments the base is at least six times as wide as the height.
[0060] In the embodiment of FIG. 9B , the sloping shape of the water-facing surface causes the water pressure to press the barrier against the ground and thereby increases friction and helps the barrier to resist being shifted horizontally by the water. The embodiment of FIG. 9B further includes an anchoring sheet 904 that is attached to the barrier and extends in front of the barrier, where it is pressed against the ground by the water 906 in front of the barrier, so that there is a high friction between the anchoring sheet 904 and the ground that further inhibits lateral movement of the barrier by the water 906 .
[0061] The anchoring sheet in the embodiment of FIG. 9B is wrapped around the forward-located modules of the barrier, thereby attaching the anchoring sheet 904 to the barrier. In similar embodiments, the anchoring sheet 904 is wrapped around the entire barrier, or is attached to the barrier by some other means known in the art.
[0062] In some embodiments, the anchoring sheet 904 is sufficiently flexible to allow it to conform closely with the underlying shape of the water-facing surface. And in some of these embodiments, the anchoring sheet 904 is made from a material that naturally clings to the water-facing surface of the barrier due to static electrical attraction.
[0063] In embodiments, the flexible material of the barrier allows the base of the barrier to form a seal with ground even if the ground is rough. The embodiment of FIG. 9B further includes a flexible underlying sheet 908 that increases resistance to puncture of the barrier from beneath, and which forms a seal with the ground so as to further resist penetration of water beneath the barrier. In some of these embodiments, the underlying sheet 908 includes a cushioning layer such as foam or a puncture-proof air bag that enables the underlying sheet to form a seal with very rough ground, and also further helps to avoid puncture of the barrier from beneath. In certain of these embodiments, the underlying sheet 908 is filled with dry sand, foam or some other compliant material that will not get wet from the flood water.
[0064] With reference to FIG. 10 , some embodiments include a ladder 1000 that provides a convenient means for crossing the barrier 300 . The ladder 1000 is configured to be free-standing, but to conform somewhat closely to the outer shape of the barrier 300 , so as to provide additional structural support to the barrier 300 by inhibiting changes to the barrier's shape. In the embodiment of FIG. 10 , the ladder 1000 further provides vertical support to the barrier 300 by including coupling features 1002 on the ladder 1000 that can be attached to complementary coupling features 1004 provided on the top of the barrier 300 .
[0065] FIG. 11 is a cross-sectional view of the embodiment of FIG. 10 , where the relationship between the ladder 1000 and the barrier 300 can be more clearly seen. A vertical offset between the ladder 1000 and the barrier 300 is included in FIG. 11 , which simplifies the illustration of the coupling mechanisms 1002 , 1004 . In other embodiments, such as the embodiment of FIG. 13 , the ladder 1000 includes little or no vertical offset from the top of the barrier 300 , and in some of these embodiments the ladder applies a small vertically downward pressure to the top of the barrier 300 .
[0066] FIG. 12 is a close-up view of the top of the embodiment of FIG. 11 , wherein the coupling features 1002 , 1004 can be more clearly seen. In FIGS. 10-12 , a strap 1004 is attached to the top of the barrier 300 , and is looped through and buckled to a rigid loop 1002 that extends from the side of the ladder 1000 . While FIGS. 10-12 present a specific example of coupling features, it will be understood that the scope of the invention includes all coupling mechanisms known in the art, such as hooks, clamps, bolted brackets, nuts and horseshoe bolts, and such like. With reference to FIG. 13 , it will also be understood that some embodiments do not include coupling of the ladder 1000 to the barrier 300 .
[0067] The foregoing description of the embodiments of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of this disclosure. It is intended that the scope of the invention be limited not by this detailed description, but rather by the claims appended hereto.
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A portable, water-filled module suitable for use as a barrier or inclusion in a barrier is internally divided into cells and emulates a section of a sandbag dike or wall without requiring sand or intensive labor to install. Automatic valves can seal openings between the filled cells, so that a punctured cell will not cause cells below and behind to deflate. Cells can project below the base into a stabilizing trench. Some embodiments can be initially filled with air, positioned, and then filled with water while the air escapes through a pressure valve. Side structures of the module can enable interlocking with adjacent modules. In embodiments, a rigid ladder spans the module to provide structural support and enable traversing of the module. The ladder can be attachable to the module. The light, flexible walls of the module can include nanofiber.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority from Japanese Patent Application No. JP-2005-284646, which was filed on Sep. 29, 2005, Japanese Patent Application No. JP-2005-342697, which was filed on Nov. 28, 2005, Japanese Patent Application No. JP-2005-377987, which was filed on Dec. 28, 2005, Japanese Patent Application No. JP-2006-081806, which was filed on Mar. 23, 2006, and U.S. Provisional Patent Application No. 60/826,254, which was filed on Sep. 20, 2006, the disclosures of which are incorporated by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to ink cartridges. In particular, the present invention is directed towards ink cartridges which may be used in combination with ink jet printers.
[0004] 2. Description of Related Art
[0005] Ink cartridges which are configured to be used in combination with ink jet printers are known in the art.
SUMMARY OF THE INVENTION
[0006] According to an embodiment of the present invention, an ink cartridge comprises a first case, and a second case enclosed within the first case. The second case comprises a particular wall, and a translucent portion extending from the particular wall in a predetermined direction. Moreover, the translucent portion has an inner space formed therein. The ink cartridge also comprises a signal blocking portion disposed within the second case, wherein the signal blocking portion is disposed within the inner space of the translucent member.
[0007] According to another embodiment of the present invention, an ink cartridge comprises a first case, and a second case disposed within the first case. The second case comprises a particular wall, an ink chamber configured to store ink therein, and an air intake portion extending from the particular wall in a predetermined direction. Moreover, the air intake portion is configured to communicate air from an interior of the ink chamber to an exterior of the ink chamber.
[0008] According to yet another embodiment of the present invention, an ink cartridge comprises a first case, and a second case disposed within the first case. The second case comprises a particular wall, and a signal blocking portion provided at the particular wall.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] For a more complete understanding of the present invention, the needs satisfied thereby, and the features and technical advantages thereof, reference now is made to the following descriptions taken in connection with the accompanying drawings.
[0010] FIG. 1 is a perspective view of an ink cartridge, according to an embodiment of the present invention.
[0011] FIG. 2 is an expanded, perspective view showing an interior of the ink cartridge of FIG. 1 , according to an embodiment of the present invention.
[0012] FIG. 3 ( a ) is a side view of a signal blocking portion of a movable member, which is disposed within an inner space of a translucent portion; FIG. 3 ( b ) is a cross-sectional view of the signal blocking portion and the translucent portion of FIG. 3 ( a ) along the XVIIIb-XVIIIb line; and FIG. 3 ( c ) is a cross-sectional view of the signal blocking portion and the translucent portion of FIG. 3 ( a ) along the XVIIIc-XVIIIc line, according to an embodiment of the present invention.
[0013] FIG. 4 ( a ) is a front view of a movable member having a float member and a signal blocking portion; and FIG. 4 ( b ) is a view of the movable member of FIG. 4 ( a ) along the arrow XIXb perspective, according to an embodiment of the present invention.
[0014] FIG. 5 ( a ) is a side view of an ink reservoir element; FIG. 5 ( b ) is a side view of the front of the ink reservoir element of FIG. 5 ( a ); and FIG. 5 ( c ) is a cross-sectional view of the ink reservoir element of FIG. 5 ( a ) along the XXc-XXc line, according to an embodiment of the present invention.
[0015] FIG. 6 is a cross-sectional view of a communication path of an ink cartridge, in which the ink cartridge is installed in a printer, according to an embodiment of the present invention.
[0016] FIG. 7 is a perspective view of an ink cartridge showing a process for attaching a protective cap to the ink cartridge, according to an embodiment of the present invention.
[0017] FIG. 8 ( a ) is a side view of an ink reservoir element showing the position of a movable member when there is ink within the ink reservoir element; and FIG. 8 ( b ) is a side view of the ink reservoir element of FIG. 8 ( a ) showing the position of the movable member when there is no ink within the ink reservoir element, according to an embodiment of the present invention.
[0018] FIGS. 9 ( a ) is a perspective view of an ink cartridge according to another embodiment of the present invention; and FIG. 9 ( b ) is a perspective view of an ink cartridge according to yet another embodiment of the present invention
[0019] FIG. 10 is a side view of an ink reservoir element, according to another embodiment of the present invention.
[0020] FIG. 11 is a side view showing a process for replacing an ink reservoir element, according to an embodiment of the present invention
DETAILED DESCRIPTION OF EMBODIMENTS
[0021] Embodiments of the present invention and their features and technical advantages may be understood by referring to FIGS. 1-11 , like numerals being used for like corresponding portions in the various drawings.
[0022] Referring to FIGS. 1, 2 , and 7 , an ink cartridge 14 may comprise an ink reservoir element/case 100 which is configured to store ink, a case 200 which may substantially cover the entire body of ink reservoir element 100 , and a protector 300 which may be attached to case 200 and protects ink reservoir element 100 when ink cartridge 14 is in transit. Case 200 may have a substantially rectangular, parallelepiped shape. In an embodiment of the present invention, ink reservoir element 100 , case 200 , protector 300 , and all of the members contained in ink cartridge 14 may comprise non-metal materials, e.g., may comprise resin materials, such that they may be burned at the time of disposal. For example, nylon, polyester, or polypropylene may be used as resin materials.
[0023] Ink reservoir element 100 may comprise a frame portion 110 which forms an ink chamber 111 which is configured to store ink, an ink supply portion 120 which is configured to supply ink stored in ink chamber 111 to a multifunction device (not shown), such as a printer, and an ambient air intake portion 130 which is configured to introduce ambient air into frame portion 110 . Ink reservoir element 100 also may comprise a translucent portion 140 which may allow for the detection of the amount of ink stored in ink chamber 111 , and a film 160 which may be welded to the top surface and the bottom surface of frame portion 110 to form an ink reservoir chamber on frame portion 110 . In an embodiment of the present invention, ink supply portion 120 and ambient air intake portion 130 each extend further from ink reservoir element 100 than translucent portion 140 .
[0024] Case 200 may comprise a first case member 210 and a second case member 220 which are configured to sandwich ink reservoir element 100 . Alternatively, case 200 may be an integral case. When case 200 comprises first case member 200 and second case member 220 , first case member 210 may be a member which covers the bottom side surface of ink reservoir element 100 , and second case element 220 may be a member which covers the top side surface of ink reservoir element 100 . First and second case members 210 and 220 may comprise at least one resin material, and may be manufactured using injection molding.
[0025] A pair of case cutout portions 211 and 212 may be provided through first case member 210 for exposing ink supply portion 120 and ambient air intake portion 130 , respectively, to the outside of case 200 . Case cutout portions 211 and 212 may be substantially semicircular. A case cutout portion 213 also may be provided through first case member 210 between case cutout portion 211 and case cutout portion 212 , and case cutout portion 213 may be for receiving a sensor (not shown) of the multifunction device at a position where the sensor sandwiches translucent portion 140 . For example, case cutout portion 213 may have a substantially square or rectangular shape. Similarly, second case member 220 may comprise case cutout portions 221 , 222 , 223 , which may correspond to case cutout portions 211 , 212 , and 213 , respectively. When first case member 210 is connected to second case member 220 to form case 200 , case cutout portions 211 and 221 may form a first opening, case cutout portions 212 and 222 may form a second opening, and case cutout portions 213 and 223 may form a third opening. Moreover, when ink reservoir element 100 is positioned within case 200 , ink supply portion 120 may protrude from the first opening, ambient air intake portion 130 may protrude from the second opening, and a portion of translucent portion 140 may be aligned substantially flush with the third opening. In an embodiment of the present invention, translucent portion 140 divides the third opening into a first opening portion 140 a and a second opening portion 140 b , which are configured to receive a light emitting portion and a light receiving portion, respectively, of the sensor.
[0026] Referring to FIG. 3 ( a ), translucent portion 140 may protrude outward from frame portion 110 . Translucent portion 140 may comprise an enclosure portion 141 which encloses the end of a movable member 470 , e.g., a signal blocking portion 473 c of movable member 470 , by sandwiching the end of movable member 470 with a pair of wall surfaces and forms a passage through which movable member 470 may be displaced. Translucent portion 140 also may comprise a translucent arm supporting portion 142 which may supports movable member 470 from below. Translucent arm supporting portion 142 may be positioned in the center of the width direction of the passage within translucent portion 140 , and it may be arranged, such that the end of movable member 470 also is positioned in the center of the passage within translucent portion 140 .
[0027] Movable member 470 may rotate based on the amount of ink within ink chamber 111 , and it may be a member which may be used in combination with the sensor to detect whether the amount of ink within ink chamber 111 is sufficient by detecting the position of signal blocking portion 473 c . The sensor may comprise a light emitting portion and a light receiving portion, and translucent portion 140 may be positioned therebetween. Therefore, when signal blocking portion 473 c is positioned in the light path between the light emitting portion and the light receiving portion, it blocks the light transmitted by the light emitting portion. Consequently, by rotating based on the amount of ink within ink chamber 111 , movable member 470 may change the amount of light received by the light receiving portion and may be used to detect the presence or absence of ink.
[0028] Referring to FIG. 3 ( b ), the thickness of translucent arm supporting portion 142 may be selected, such that a gap t 4 between the inside walls of enclosure portion 141 and the outside wall of translucent arm supporting portion 142 may be less than a gap t 3 between the inside walls of enclosure 141 and the outside of movable member 470 . When liquid surface I of the ink falls below translucent portion 140 , the ink within translucent portion 140 may be depleted, however, because gap t 3 between movable member 470 and enclosure 141 may be relatively small, ink may remain within translucent portion 140 due to the surface tension of the ink, and movable member 470 may not rotate normally due to the surface tension of the ink. Nevertheless, by forming arm supporting portion 142 , such that gap t 3 is greater than gap t 4 , capillary force generated between translucent arm supporting portion 142 and enclosure portion 141 may be greater than the capillary force generated between movable member 470 and enclosure portion 141 . Consequently, the ink which remains within enclosure portion 141 may be drawn between arm supporting portion 142 and enclosure portion 141 , such that it may be possible to substantially prevent ink from remaining between movable member 470 and enclosure portion 141 . As such, the amount of ink may be accurately detected.
[0029] Referring to FIGS. 4 ( a ) and 4 ( b ), movable member 470 may be a member for detecting the amount of ink within ink chamber 111 . Movable member 470 may be manufactured by injection molding using a resin material, e.g., polypropylene, and it has light-blocking properties, e.g., it may be opaque. Movable member 470 may be a rotating member which rotates based on the amount of ink within ink chamber 111 , and a portion of movable member 470 may be detected by the sensor which detects the amount of ink stored within ink chamber 111 . Movable member 470 may comprise a float portion 471 which may comprise a material with a specific gravity which is less than the specific gravity of ink, a pivot portion 472 which may be attached to frame portion 110 , such that it may pivot, and an arm portion 473 , which extends from pivot portion 472 in a direction which may be substantially orthogonal to float portion 471 . Pivot portion 472 may be a linking portion which connects float portion 471 and arm portion 473 . In operation, when movable member 470 rotates upward, movable member 470 contacts a ceiling surface of translucent portion 140 , and the rotation of movable member 470 may be restricted. Therefore, it may be possible to prevent movable member 470 from moving out of translucent portion 140 .
[0030] Arm portion 473 may comprise a vertical arm portion 473 a which extends in a direction which is substantially perpendicular to float portion 471 , a sloping arm portion 473 b which slopes upward from vertical arm portion 473 a , and a signal blocking portion 473 c , which may be used as a light-blocking portion which blocks the light transmitted by the light emitting portion of the sensor.
[0031] Referring to FIG. 4 ( b ), arm portion 473 may be substantially thinner than float portion 471 and pivot portion 472 . Specifically, if arm portion 473 has a thick profile, the scale of translucent portion 140 may be increased, and consequently, the size of ink cartridge 14 and the resistance when movable member 470 rotates also may increase, which makes it difficult to accurately detect the amount of ink. Further, when the thickness of translucent portion 140 increases, the gap between the light emitting portion and the light receiving portion of the sensor widens accordingly, and the detection sensitivity deteriorates, which increases the costs associated with the sensor. Therefore, arm portion 473 may have a relatively thin profile. A plurality of ribs 473 d may be provided on vertical arm portion 473 a and sloping arm portion 473 b , which may increase the strength of arm portion 473 .
[0032] A pair of substantially semispherical arm protruding portions 473 e 1 and 473 e 2 may be provided on signal blocking portion 473 c on the top and the bottom of the portion housed within translucent portion 140 , respectively. Arm protruding portions 473 e 1 and 473 e 2 may reduce the likelihood of signal blocking portion 473 c adhering to the inside wall of translucent portion 140 due to the surface tension of the ink. For example, because arm protruding portions 473 e 1 and 473 e 2 may have a substantially semispherical shape, the only portion which contacts the inside wall of translucent portion 140 may be the end of arm protruding portions 473 e 1 and 473 e 2 , such that the effects of the surface tension of the ink may be reduced.
[0033] Float portion 471 may comprise a resin material with a specific gravity which is less than the specific gravity of ink, such that when liquid surface I of the ink is lowered, float portion 471 moves in the direction of the bottom portion of frame portion 110 , i.e., float portion 471 and liquid surface I of the ink move in the same direction as ink is dispensed. When float portion 471 moves in the direction of the bottom portion, and arm portion 473 moves in the direction of the top portion using pivot portion 472 as a rotational axis, the signal blocking portion 473 c may move out of between the light emitting portion and the light receiving portion and therefore, the state in which ink is depleted may be detected. Moreover, when the specific gravity of the materials comprising float portion 471 are less than the specific gravity of ink, it may be unnecessary to manufacture complex dies, such that the manufacturing cost of movable member 470 may be reduced.
[0034] Referring to FIGS. 5 ( a ), and 5 ( b ), ink supply portion 120 , ambient air intake portion 130 , and translucent portion 140 may be provided on one of the side surfaces of frame portion 110 . When ink cartridge 14 is installed within the multifunction device, ambient air intake portion 130 , translucent portion 140 , and ink supply portion 120 may be sequentially aligned from top to bottom.
[0035] Referring to FIG. 5 ( a ), a width t 5 of translucent portion 140 may be less than a diameter t 6 of the opening of ink supply portion 120 , and a length t 7 of translucent portion 140 may be greater than width t 5 of translucent portion 140 . Referring to FIG. 5 ( b ), translucent portion 140 may be receded in the direction of frame portion with respect to ink supply portion 120 and ambient air intake portion 130 . A width t 8 of translucent portion 140 may be greater than width t 5 of translucent portion 140 .
[0036] Arm portion 473 of movable member 470 may be positioned within the inner space of translucent portion 140 , and the light path of the sensor may be opened from the light-blocking state due to the rotation of arm portion 473 , and the amount of ink may be detected. The light receiving portion and the light emitting portion may be positioned on both sides of translucent portion 140 , such that both side surfaces of translucent portion 140 form detection surfaces 140 a and 140 b . Referring again to FIG. 5 ( a ), detection surfaces 140 a and 140 b may be parallel to the height direction, e.g., Y-direction, of ink cartridge 14 when ink cartridge 14 is installed in the multifunction device.
[0037] When ink adheres to detection surfaces 140 a and 140 b , it may be difficult to accurately detect the amount of ink. Referring to FIG. 5 ( b ), translucent portion 140 may be provided in a position withdrawn to the side of ink chamber 111 with respect to ink supply portion 120 , such that it may be difficult for ink to adhere to translucent portion 140 even when ink drips from ink supply portion 120 . Specifically, the ink which drops from ink supply portion 120 generally may not head towards translucent portion 140 , such that it does not adhere to translucent portion 140 .
[0038] Because detection surfaces 140 a and 140 b are vertical when ink cartridge 14 is installed in the multifunction device, the ink may be most susceptible to the effects of gravity when ink cartridge 14 is installed in the multifunction device. Therefore, even if the ink has adhered to detection surfaces 140 a and 140 b , it drops relatively quickly. It therefore may be possible to substantially avoid the transfer of ink to the light receiving portion and the light emitting portion of the sensor. Moreover, the ink which drops from detection surfaces 140 a and 140 b may not adhere to the end surface of ink supply portion 120 .
[0039] Referring to FIG. 5 ( c ), side walls which form detection walls 140 a and 140 b extending from the side surface of frame portion 110 may be provided on translucent portion 140 . Therefore, an edge portion 140 c where the side surface of frame portion 110 and detection surfaces 140 a and 140 b intersect may be provided at a substantially perpendicular angle. When ink adheres to the vicinity of edge 140 c , the capillary force of edge 140 c acts upon the ink because edge 140 c may be provided at a substantially perpendicular angle, and the ink may flow towards ink supply portion 120 along edge 140 c . It therefore may be possible to reduce the adherence of ink to detection surfaces 140 a and 140 b.
[0040] When ink cartridge 14 is installed in the multifunction device, ink cartridge 14 may be installed, such that ink supply portion 120 is located below ambient air intake portion 130 . This state may be the installation position of ink cartridge 14 . Moreover, when ink cartridge 14 is installed in the multifunction device, ink supply portion 120 , translucent portion 140 , and ambient air intake portion 130 may be sequentially positioned from bottom to top, and ink supply portion 120 , translucent portion 140 , and ambient air intake portion 130 may be provided on a single end surface. Therefore, because ink supply portion 120 , translucent portion 140 , and ambient air intake portion 130 are provided, such that they are focused, e.g., positioned adjacent to each other, on a single end surface, the sensor, a needle configured to be connected with the ink supply portion (not shown), and a passage configured to be connected with air intake portion 130 (not shown) associated with the multifunction device may be consolidated on a single surface, such that the size of the multifunction device may be reduced.
[0041] Ink supply portion 120 and translucent portion 140 may be sequentially provided on the single end surface from top to bottom, and by using movable member 470 for detecting ink, the ink may be used to the fullest extent. For example, when the amount of ink is detected by irradiating a portion of the ink cartridge using a photo-detector, if a method in which the presence of ink may be detected directly were used, the ink could not be fully used with a configuration in which the ink supply opening and the irradiated portion which may be irradiated by photo-detector are both provided on a single end surface, as in this embodiment. Specifically, if the irradiated portion is positioned below the ink supply opening, the position of the ink supply opening becomes relatively high, such that ink which is stored below the ink supply opening may not be used. Conversely, if the irradiated portion is positioned above the ink supply opening, the position of the irradiated portion becomes relatively high, such that a significant quantity of ink may be inside the ink cartridge when the photo-detector detects the absence of ink. Nevertheless, in this embodiment, movable member 470 may be used, such that even when the irradiated portion is provided in a relatively high position, the absence of ink may be detected in step with the timing in which the actual amount of ink becomes low, and the ink supply opening may be provided in a low position, such that there may be an insignificant amount of ink inside the ink cartridge when the absence of ink is detected.
[0042] Referring to FIGS. 3 ( a ), 8 ( a ), and 8 ( b ), when ink cartridge 14 is installed in the multifunction device, the light emitting portion and the light receiving portion of the sensor may be positioned at positions sandwiching translucent portion 140 . Because signal blocking portion 473 c of movable member 470 may be positioned in enclosure portion 141 of translucent portion 140 , the ink quantity may be detected by the operation of movable member 470 .
[0043] The direction of rotation of movable member 470 may be determined based on the combined force of the buoyancies and gravities acting on the right side portion and the left side portion. Nevertheless, in order to simply the description of sensor 470 , it is assumed that all of the forces which act on movable member 470 also act on float portion 471 . Based on this assumption, the rotation of movable member 470 is determined by the buoyancy and the gravity acting on float portion 471 . When there is a large amount of ink stored in ink chamber 111 , because float portion 471 of movable member 470 may comprise resin material with a lower specific gravity than the specific gravity of ink, the buoyancy generated on float portion 471 increases, and float portion 471 floats in the ink. The combined force of gravity and buoyancy generated on float portion 471 causes a rotating force to be received in the clockwise direction in FIGS. 3 ( a ), 8 ( a ), and 8 ( b ). Nevertheless, signal blocking portion 473 c contacts arm supporting portion 142 , and thus, signal blocking portion 473 c may be positioned in a position blocking the optical path between the light emitting portion and the light receiving portion of the sensor.
[0044] As the ink within ink chamber 111 decreases in quantity, the surface level I of the ink drops. As the surface level I of the ink drops, signal blocking portion 473 c emerges on the surface level I of the ink, and subsequently, float portion 471 also emerges on the surface level I of the ink. When float portion 471 emerges on the surface level I of the ink, the buoyancy generated on float portion 471 , which causes movable member 470 to rotate in the clockwise direction in FIGS. 3 ( a ), 8 ( a ), and 8 ( b ), and the gravity generated on float portion 471 , which causes movable member 470 to rotate in the counterclockwise direction in FIGS. 3 ( a ), 8 ( a ), and 8 ( b ), balance each other out, such that the overall combined force may be balanced. Subsequently, as the surface level I of the ink drops further, float portion 471 moves downward following the surface level I, such that movable member 470 rotates counterclockwise. The rotating operation causes signal blocking portion 473 c to move upward away from arm supporting portion 142 , and an optical path may be created between the light emitting portion and the light receiving portion of the sensor. In this state, a controller (not shown) of the multifunction device determines that ink cartridge 14 is out of ink.
[0045] As the quantity of ink transitions from a substantial amount of ink to substantially no ink, float portion 471 may transition from an upper position to a lower position within ink chamber 111 . Thus, when the quantity of ink in ink chamber 111 is low, an out-of-ink discrimination accurately may be detected.
[0046] Referring to FIG. 6 , a communication path 116 may be formed within ink cartridge 14 , and ink may flow through communication path 116 as indicated by arrow K. Communication path 116 may be in fluid communication with ink chamber 111 and ink supply portion 120 , and may be configured to dispense ink from an interior of ink chamber 111 to an exterior of ink chamber 111 via an opening formed in ink supply portion 120 . Communication path 116 may be substantially perpendicular to the wall on which ink supply portion 120 , ambient air intake portion 130 , and translucent portion 140 are formed.
[0047] Referring to FIG. 9 ( a ), an ink cartridge 4014 according to yet another embodiment of the present invention is depicted. Ink cartridge 4014 may have a through-hole 4130 for admitting ambient air into ink cartridge 4014 provided in a portion of its top surface. The air admitted through through-hole 4130 may pass through a labyrinth shaped air intake passage 4131 and may be admitted within ink cartridge 4014 . A seal member 4132 may be glued to ink cartridge 4014 to prevent deaeration and outflow of ink within ink cartridge 4014 before use. To use ink cartridge 4014 , seal member 4132 may be peeled off, and then the cartridge is installed the multifunction device.
[0048] A portion 4140 may be a protrusion provided outward from one end surface extending substantially in the vertical direction of ink cartridge 4014 , and below which may be provided ink supply portion 4120 . Portion 4140 may be translucent. An ink supply opening 4121 into which a needle of the multifunction device may be inserted may be provided on the protrusion tip of ink supply portion 4120 . Ink cartridge 4014 may not have a structure corresponding to ink reservoir element 100 , and stores the ink directly within the case. A movable member like movable member 470 may be provided within ink cartridge 4014 and a signal blocking portion of the movable member may be positioned within portion 4140 . Alternatively, portion 4140 may not be translucent, e.g. opaque, and the movable member may not be within the ink cartridge. In this case, an ink amount in ink cartridge 4014 may not be detected by the sensor. However, at least presence and absence of ink cartridge 4014 can be detected by the sensor because portion 4140 blocks the light emitted from the light emitting portion of the sensor when ink cartridge 4014 is installed in the multifunction device.
[0049] Referring to FIG. 9 ( b ), an ink cartridge 5014 according to still yet another embodiment of the present invention is depicted. Ink cartridge 5014 may be substantially the same as ink cartridge 4014 , except that ink supply portion 4120 has been replaced by ink supply portion 5120 .
[0050] Referring to FIG. 10 , an ink reservoir element 9300 according to another embodiment of the present invention is depicted. Ink reservoir element 9300 may be substantially similar to ink reservoir element 100 . Therefore, only the differences between ink reservoir element 9300 and ink reservoir element 100 are discussed with respect to ink reservoir element 9300 . Ink reservoir element 9300 may be fixed within the first and second case members. Ink reservoir element 9300 may comprise a hard portion 9301 which may be provided through injection molding using a resin material, and a bag element 9302 connected to hard portion 9301 , which may be a flexible element which forms a reservoir space for storing ink therein. Hard portion 9301 may comprise a detection portion 9303 which may be configured to be positioned between the light emitting portion and the light receiving portion of the sensor. In operation, when the ink within bag portion 9302 is reduced, bag portion 9302 may shrink in response to the reduction in ink, and the ink is substantially depleted, the reservoir space also may be substantially depleted. Therefore, it may be difficult to position a movable member within bag portion 9302 to detect the amount of ink remaining within bag portion 9302 .
[0051] Moreover, hard portion 9301 may have light barrier properties, and because it may be positioned between the light emitting portion and the light receiving portion, it may block the emitted light which is emitted from the light emitting portion. Therefore, it may be possible to detect whether there is an ink reservoir element 9300 contained within the first and second case members, and as such, it may be possible to prevent printing processes from being performed by the multifunction device when no ink reservoir element 9300 is present.
[0052] Referring to FIG. 11 , in each of the above-described embodiments of the present invention, at least one wall of first case member 210 may be secured to at least one corresponding wall of second case member 220 via an adhesive member 9100 , such that it is possible to open and to close first case member 210 and second case 220 with adhesive member 9100 functioning as a hinge member for first case member 210 and second case member 220 . Therefore, ink reservoir element 100 or 9300 may be replaced by separating a portion of first case member 210 from a corresponding portion of second case member 220 without separating first case member 210 entirely from second case member 220 .
[0053] While the invention has been described in connection with exemplary embodiments, it will be understood by those skilled in the art that other variations and modifications of the exemplary embodiments described above may be made without departing from the scope of the invention. Other embodiments will be apparent to those skilled in the art from a consideration of the specification or practice of the invention disclosed herein. It is intended that the specification and the described examples are considered merely as exemplary of the invention, with the true scope of the invention being indicated by the flowing claims.
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An ink cartridge includes a first case, and a second case enclosed within the first case. The second case includes a particular wall, and a translucent portion extending from the particular wall in a predetermined direction, Moreover, the translucent portion has an inner space formed therein. The ink cartridge also includes a signal blocking portion disposed within the second case, wherein the signal blocking portion is disposed within the inner space of the translucent member.
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This application is a continuation-in-part of application Ser. No. 346,958 of Feb. 8, 1982, now U.S. Pat. No. 4,383,928 issued May 17, 1983, which itself was a continuation-in-part of now-abandoned application Ser. No. 215,694 of Dec. 12, 1980.
This invention relates to a process for the treatment of aqueous latex wastes, typically those from manufacturing, packaging, and using surface coatings containing a film-forming latex vehicle. The economic disposal of such wastes in a leach-resistant condition has become an important aspect of plant operation.
BACKGROUND OF THE INVENTION
These latices commonly have an average molecular weight of 100,000 or more. They are stable suspensions whose average latex particle size typically is about 2,000-5,000 Å, or even larger. Latex concentration in the waste dealt with here ordinarily is about 1-6% by weight; rarely does it reach as much as 20%. While such latices may at times have a bit of ionic functionality in their molecular structures, they are to be distinguished from the more highly ionizable lyophobic colloid-type coating resins and resinous mixtures made for aqueous dispersion such as those shown in Example 1 of our parent application Ser. No. 346,958. The latter resins typically have average molecular weight below 40,000, and they disperse into water in a much finer particulate condition.
In said parent application we have shown a practical way to form a leach-resistant consolidate of low volume from the thinly-dispersed, comparatively low molecular weight resinous material and from latex wastes that are structurally fairly acidic or, if practically neutral, are deliberately acidulated. The process of said parent application involves using portland cement to flocculate the dispersoid and collecting the resulting small volume cementiferous floc. Such processing is to be distinguished from prior proposals for converting an initial volume of waste water (including one containing dispersed polymer) into a massive concretion with portland cement and aggregate (for example, as shown in U.S. Pat. Nos. 4,116,705 and 4,149,968). Such resulting concretion (for landfill or other disposal) can be larger than the original volume of the aqueous waste submitted to treatment.
Heretofore it has been proposed to flocculate and settle latex for disposal using, for example, flocculants including complex organic ones. Such processes are slow, often expensive, and frequently they produce a waste mass or sludge that can be difficult to handle, In our U.S. Pat. No. 4,132,759 of Jan. 26, 1982, we have shown an efficient way to form a leach-resistant consolidate from aqueous latex paint wastes. The process involves flocculating such waste with an organic flocculating agent, then heating the waste body to a fairly high temperature. The process is reasonably rapid. The sludge consolidates well, and it can be handled with facility.
The instant invention is distinguishable from the process of our U.S. Pat. No. 4,132,759 in that it uses a little cement, rather than the heating of the entire aqueous waste mass, in the process of obtaining the leach-resistant consolidate; the resulting consolidate is a more brittle one (because of the cement addition). Unlike the process of the parent application here, the cement in the instant operation can be used in a much lesser effective proportion, and it is not used as a flocculant, but rather to enhance, surprisingly, the separability of a floc already initiated. The resulting cementiferous sludge is of relatively minor volume in comparison to the volume of the aqueous waste submitted to such treatment. This, of course, is in sharp contrast to concretion processes referred to above which employ cement.
BROAD STATEMENT OF THE INVENTION
Our invention for treating a body of waste water contaminated with a low concentration of suspended latex comprises: destabilizing the latex of said body into a floc of small particulates; enhancing separability of said floc by blending a small proportion of portland cement into the destabilized suspension; and separating resulting cementiferous sludge from remaining aqueous material.
DETAILED DESCRIPTION OF THE INVENTION
The portland cement for this process can be any common type of such cement. Desirably it has a Blaine number of at least about 3,000 sq. cm./gm. It need not have good light color, but can be an ordinary grayish sort.
The latex solids for removal by the instant process can be various. Typically they are used as film-forming binders in surface coatings or paint. In the latter aspect they can be associated with the usual fillers, opacifying and/or coloring pigments, and other conventional latex paint ingredients. Latices having acrylic monomer incorporated into their molecular structure are the most common and present most of the disposal problems today, particularly those having a small hydroxylated and/or carboxylic acid monomer unit content. Many of this sort find industrial application in coil coatings, board coatings, primers and topcoats. Aqueous wastes from these operations often are vexing to dispose of, especially ones that are alkaline.
Aqueous latex dispersions can be destabilized in a variety of ways. The addition of flocculating agents such as complex organic ones has already been mentioned. Alums and other conventional water-soluble inorganic flocculants are quite inexpensive, and they are advantageous in the instant process for efficiency and economy. Of these we prefer most highly technical grades of papermakers alum, empirically Al 2 (SO 4 ) 3 .18H 2 O, and potash alum, empirically K 2 Al 2 (SO 4 ).24H 2 O, for just such reasons.
In the destabilization we find it advantageous to use such inorganic flocculant in as high a dilution as is effective for initiating the formation of a tiny, grainy floc (floccules). Concentrated addition of such flocculant, as in powder or concentrated solution form, tends to give a large volume, amorphous-looking floc which is disadvantageous for further processing. The dosage of preferred flocculant need not be substantially in excess of about a gram of equivalent aluminum per gallon of the body of waste water submitted to treatment; advantageously it is much lower, e.g. about 0.1-0.2. We have found it quite practical to use aqueous flocculant solutions containing about 1-3% by weight of the preferred flocculants for in-plant use, and, to preclude operator errors with the possible obtention of a messy, amorphous-appearing floc, the aqueous solution of aluminum sulfate and/or potassium-aluminum sulfate should not be in a concentration that contains substantially more than about 2% of equivalent aluminum. Other useful water-soluble inorganic flocculants include sodium aluminum sulfate, ferric sulfate, ferrous sulfate, ferric ammonium sulfate, ferric chloride, sodium aluminate, and even hydrated or partially hydrolyzed aluminum chloride (although chlorine-bearing materials tend to be corrosive toward steel equipment and iron-bearing flocculants can give rise to undesirable coloration in effective dosages and therefore are not preferred). Advantageously the dilute flocculant solution is added into the destabilized latex aqueous body with moderate stirring; extended and/or high intensity mixing tends to break up flocs, and that can be counterproductive in the instant operation.
The operation can be done effectively at room temperature, e.g. 60°-80° F., in small or large vessels and at atmospheric pressure for efficiency and economy. Ordinary mild steel equipment is preferred where corrosion tendencies are not evident. When the latex in the body of waste water has been destabilized into a floc of small particles, the portland cement can be stirred in. A practical proportion of cement generally for in-plant use is one that is roughly equal to the weight (dry basis) of the suspended latex present in the waste water to obtain effective and foolproof operation. It rarely is less than about a 0.2 pound per pound of the latex in the body of the waste water treated. At the expense of more cement, the cement proportion can be raised to about 2 pounds per pound of latex in said body (where a more brittle precipitate is desired or the waste water is richer than ordinary in suspended latex).
The cement appears to agglomerate the small particulates of the floc, and, because of this agglomeration, separability of the floc from remaining aqueous material is considerably enhanced. The settling rate is decidedly increased because of this agglomeration and probably also because of density added by the cement; the cementiferous sludge dewaters and consolidates well. While such sludge can be separated from resulting clarified water by conventional filtration or centrifugation, we find it less expensive and quite adequate simply to allow the floc to settle as a sludge, then consolidate for a number of hours. A clarified supernatant water can be decanted with ease. In 16 to 24 hours (or even longer) the sludge embrittles. If, while still slack and tractable, the sludge is formed into a block even with the possible addition of a filler such as sand, it could be used as a structural unit. However, ordinarily the resulting consolidate simply is disposed of as landfill. Such consolidate does not tend to adhere to the vessel in which it is formed, and it can form under water.
The following examples show how the invention has been practiced, but should not be construed as limiting it. In this specification all parts are parts by weight, all percentages are weight percentages, and all temperatures are in °F. unless otherwise expressly indicated.
EXAMPLE 1
Wash water from the manufacture of an exterior acrylic latex paint was the waste processed. The waste had an amino odor, and its pH was about 9; it contained about 31/2% of the latex in stable suspension. To 850 parts of this wash water there was added, with stirring, 25 parts of a 2% by weight aqueous solution of technical grade potash alum. The stirring was continued for 5 minutes to generate an initial floc of small, grainy particulates, and into this was blended 30 parts of Allentown Type I portland cement having Blaine No. of 3,200. After 2 more minutes the stirring was discontinued, and the floc was allowed to settle for 2 hours. The resulting clear supernatant liquid was decanted off, and the remaining settled slack sludge was allowed to consolidate in place at room temperature. The volume of such supernatant liquid was about 80% of that of the original wash water and the sludge about 20%. The sludge hardened in 24 hours into a brittle solid, and a very small amount of remaining clear aqueous serum was poured off.
EXAMPLE 2
The process of claim 1 was repeated, but this time the flocculation was done with 25 parts of a 2% by weight aqueous solution of papermakers alum. The results were virtually the same.
EXAMPLE 3
An aliquot of the brittle sludge of Example 1 was dried for about 3 hours in an 180° F. oven. (This approximates about a week of air drying of such sludge.) The dried sample was submitted for Extraction Procedure Leachate analysis as prescribed by the Resource Conservation and Recovery Act (RCRA) to determine its resistance to leaching in a landfill.
The leachate analysis was made by an independent laboratory in accordance with EPA Extraction Procedure. In this preparation 100 grams of the dried sludge was ground up and placed into 1,600 ml. of high purity water and stirred for 24 hours. The initial pH was 11.4. 400 ml. of 0.5N acetic acid was added to the slurry. The final pH was 11.1. The slurry, diluted to 2,000 ml., was filtered through a 0.45 micron filter. Its analysis is listed below under the column labeled "Actual Value".
______________________________________Contaminant Actual Value EPA* MCL______________________________________Arsenic, Mg./L as As 0.002 (2 ppm) 5.0Barium, Mg./L as Ba 0.630 100.0Cadmium, Mg./L as Cd 0.030 1.0Chromium, Mg./L as Cr 0.170 5.0Lead, Mg./L as Pb 0.400 5.0Mercury, Mg./L as Hg 0.0005 0.2Selenium, Mg./L as Se 0.002 1.0Silver, Mg./L as Ag 0.060 5.0______________________________________ *The values listed in this column are 100 times the "Maximum Contaminant Levels" as set by the Safe Water Drinking Act.
From the foregoing analysis it can be seen that the consolidate would qualify for disposal in a municipal landfill having an asphalt liner and a leachate basin. It contained substantially less contamination than is permitted by RCRA standards as specified by the U.S. Environmental Protection Agency.
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The separability of latex floc dispersed in water is improved by adding a small proportion of portland cement thereto.
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INTRODUCTION
[0001] The present invention relates to a silencing apparatus to fit between an air intake duct for combustion air, for instance combustion air released from an engine turbine and an air exhaust duct through which air or combustion fluid exits, for instance towards a thermal exchanger.
BACKGROUND
[0002] Silencing apparatus of this type are already known from the prior art. According to the prior art, said silencing apparatus usually comprise a main hollow boy with a circular, cylindrical shape and both an input connection and an output connection also respectively with a circular, cylindrical shape, each of which having a diameter smaller than the diameter of said main body, such that said input connection and output connection are fitted to either side of said main body.
[0003] At least one part forms a partition with the internal surface of said main hollow body, wherein said partition defines at least two toric chambers within the internal volume of said main body, which are defined between the diameter of said body and the diameter of said connections in a transversal perspective. Said toric chambers communicate directly with a virtual cylinder, which is defined by the diameter of said connections and within which the fluid moves from one connection to the other. by means of a circular slit which extends over the entire periphery of said virtual cylinder.
[0004] The apparatus according to the prior art feature many disadvantages. Firstly, the dimensions of said circular slits are too large in order to facilitate the manufacturing process. Increased losses of the inherent charge of the fluid transiting within the resonance chambers thus occur as air transits between said input connection and said output connection.
[0005] Moreover, the positioning of said partitioning part is critical when implementing this type of silencing apparatus. The width of said toric chambers must indeed precisely depend upon the frequency of the sound waves to be absorbed. Consequently, said part must be very accurately positioned. This is a time-consuming task, which is a problem within the scope of mass manufacturing. Finally, the manufacturing process of said main hollow body is itself complicated.
[0006] The present invention aims to remedy the above disadvantages by providing a new silencing apparatus fitted between an air intake duct and an air or fluid exhaust duct, which is easy to manufacture and notably does not require many stamping tools, whilst also reducing said loss of charge within said silencer.
DISCLOSURE
[0007] According to a preferred embodiment of the present invention, the silencing apparatus is fitted between a first air or fluid intake duct and a second air or fluid exhaust duct, said silencing apparatus being notably fitted between an engine turbine and a thermal exchanger; said silencer comprising a cylindrical main hollow body, a cylindrical input connection and a cylindrical output connection with a smaller straight section than the straight section of said main body, and at least one partitioning part defining with the internal surface of said main hollow body at least two toric chambers within the portion of said main body located around the virtual cylinder defined by the virtual extension of each of said connections toward one another, each of said toric chambers communicating directly with said virtual cylinder following a slit extending over the entire periphery thereof; is characterized in that said toric chambers are partly separated from said virtual cylinder by said partitioning part and/or one and/or both ducts between which said silencer is fitted.
[0008] The external walls of both the input connection and the output connection and an auxilliary wall formed by the partitioning part, which separates both chambers shaped as a body are used in order to minimise the dimension of the communicating slit between said chambers in the direction of the flow as well as the main flow of fluid, such that the incidental loss of charge is reduced in a simple manner without however requiring additional tools or parts.
[0009] In an improved embodiment of the present invention, one or a plurality of partitioning parts are cylindrical parts, the generating curvature of which includes a first straight segment defining a separating wall between the toric chambers and the virtual cylinder, a second straight segment defining a separating wall between two toric chambers and a third straight segment defining a corner with said second segment in a perspective parallel to the flow of fluid. An annular recess is shaped within the internal surface of the hollow body and said corner butts against a lateral wall of said recess such that an accurate positioning of the partitioning part is easily achieved when said third segment is welded to said recess. Accordingly, an accurate dimension of the resonance chambers is also easily achieved, whereby mass manufacturing is thus possible without however having to precisely measure the positioning of the partition for every instance.
[0010] In an improved embodiment of the present invention, the dimension of the width of said recess equals the dimension of said third straight segment of said partitioning part. The precision of the positioning is thus increased.
[0011] In an improved embodiment of the present invention, said main hollow body comprises two identical bells which can be joined to one another at the level of their respective outer edge.
[0012] In an improved embodiment of the present invention, said bells comprise a cylinder, the generating curvature of which comprises a first straight segment parallel to the flow axis and corresponding to a diameter equal to the diameter of the input duct or output duct, a second straight segment parallel to said first straight segment but farther away from the axis of said cylinder, and a third straight segment farther away still from the axis of said cylinder such that a recess is defined with the third segment of the other bell in the perspective of the axis of said cylinder, ie. the axis of the flow of fluids.
[0013] In an improved embodiment of the present invention, a third auxiliary toric chamber is implemented which communicates with the inside of said virtual cylinder by means of an aperture extending over less than three hundred and sixty degrees, notably less than two hundred and forty degrees, preferably less than one hundred and twenty degrees.
[0014] In an improved embodiment of the present invention, said third chamber is implemented by adding a second partition with a shape identical to the shape of the first partition.
FIGURES
[0015] The invention is illustrated with reference to the following drawings in which
[0016] [0016]FIG. 1 shows a first embodiment of an apparatus according to the present invention; and
[0017] [0017]FIG. 2 shows another embodiment of an apparatus according to the present invention.
DESCRIPTION
[0018] A silencing apparatus is described in FIG. 1, wherein said silencer is fitted between an air intake duct 1 which is otherwise connected to the turbine of an engine (not shown) and an exhaust duct 2 connected directly or indirectly to a thermal exchanger by means of further ducts. Air flows between duct 1 and duct 2 The apparatus can also be used with an inverse airflow, whereby duct 2 is the air intake duct and duct 1 is the exhaust duct. It is an aim of the silencing apparatus to suppress or absorb noise generated by the turbine of the turbo engine. The well-known technique of the Helmholtz resonator is herein employed for this purpose The silencing apparatus comprises a main hollow body 3 with a circular cylindrical shape. Said circular cylindrical main body comprises a first circular cylinder 4 forming the intake connection, a second circular cylinder 4 ′ forming the exhaust connection, a third circular cylinder 5 , a fourth circular cylinder 5 ′ and a fifth circular cylinder 6 , wherein said cylinders 5 , 5 ′ and 6 define the internal portion of said silencing apparatus. The diameter of said circular cylinder 6 is slightly larger than the diameter of circular cylinders 5 and 5 ′. for instance between 0.2 mm and 5 mm. A cylindrical part 8 defines two Helmholtz chambers 9 and 10 within the main body. Said partitioning part 8 is a cylindrical part. the generating curvature in the perspective of the figure, i.e. the perspective parallel to the flow of fluid, of which comprises a first straight segment 11 parallel to the flow axis, a second intermediary straight segment 12 defining a partition and a third straight segment 13 which is farther way from the axis than the fist straight segment 11 . The chamber 9 is delimited by the wall of the main body, the partition 12 and the straight segment 11 . in the perspective of the figure. Said chamber 9 has a toric shape defined at a distance of the flow axis which is equal to the diameter of the connections and the ducts, and communicates with the virtual cylinder defined by both ducts 1 and 2 by means of an annular slit 14 .
[0019] Moreover, chamber 10 is delimited by the wall of the external body on the one side and, on the other side, by the partition 12 and the portion of the wall of the duct 2 which stands out inside the hollow body. Said chamber 10 communicates with the inside of said virtual cylinder by means of an annular slit 15 . The length of the straight segment 13 is preferably equal to the width of cylinder 6 in this perspective. Said cylinder 6 is welded to cylinder 13 by welding or brazing.
[0020] The corner that arises from the junction of segments 12 and 13 butts against the lateral walls of the recess 6 , such that part 8 can be accurately positioned relative to the hollow body. The fact that the width of cylinder 6 is preferably equal to the width of cylinder 13 further ensures that the positioning of part 8 relative to the hollow body is always the same, when said part 8 is welded at the level of cylinder 6 . Connections 4 and 4 ′ have diameters slightly larger than the diameters of ducts 1 and 2 and are welded thereto after having been slid therein.
[0021] The silencer (the hollow body and the partitioning part) is made of stainless steel, with a thickness of 0.6 or 0.8 mm.
[0022] The hollow body comprises two halves, which take the shape of two bells. Each bell comprises a first small circular cylinder, a second circular cylinder with a larger diameter and a third circular cylinder with a diameter slightly larger than the second. The third circular cylinder with a larger diameter can be formed about the second circular cylinder by stamping. Both halves are joined at their outer edge at the level of the welding joint and the third cylinders of both bells form the positioning cylinder 6 once they have been welded to one another at the level of their outer edge 22 .
[0023] The positioning of the two half-bells relative to the two ducts 1 and 2 is achieved by means of grooves 20 , 21 (only shown in FIG. 1 but which may also be implemented in FIG. 2) implemented on the periphery of each duct 1 and 2 , for instance three grooves at one hundred and twenty degrees from one another. The outer edges of connections 4 and 4 ′ butt against said grooves such that the accurate positioning of said two connections relative to the two ducts they are to be inserted in is achieved before said connections are welded to said two ducts. An accurate positioning of the body of said silencing apparatus is therefore obtained relative to ducts 1 and 2 , and thus an accurate width of said communicating slits between the toric chambers and the virtual cylinder is also obtained.
[0024] An alternative embodiment of a silencing apparatus according to the present invention is shown in FIG. 2. The parts thereof which are identical to the parts shown in FIG. 1 are designated with the same reference numbers.
[0025] Said alternative embodiment is a variation of the preferred embodiment by means of implementing a second partitioning part 8 ′. the shape of which is identical to the shape of the first partitioning part 8 , and also implementing a third toric chamber 30 . Said third toric chamber 30 only communicates with the inside of the exhaust duct 2 by means of a rectangular aperture 31 extending over one hundred and twenty degrees of the periphery of said exhaust duct 2 . This embodiment confers a relatively low resonance frequency to chamber 30 compared to the frequencies of chambers 9 ′ and 10 ′, such that the range of frequencies said silencing apparatus acts upon is increased.
[0026] Said chamber 30 does not in fact perform its function according to the principle of a Helmholtz resonator but according to the principle of a tube opened at each extremity, whereby said extremities are joined at the same connecting point.
[0027] Said part 8 ′ is close to duct 2 by means of its segment 11 ′. However, they may be welded to one another or not, as shown in FIG. 2. Indeed, some slackness between both parts does not prejudice acoustical properties. Segments 13 and 13 ′ of partitioning parts 8 and 8 ′ respectively have the same dimensions, i.e. half of the width of the annular recess 6 .
[0028] An extremity of each of segments 13 and 13 ′ (i.e. the extremities forming a corner with segments 12 and 12 ′ respectively) butts against its respective stopper formed by the lateral walls of said recess 6 . Both parts 8 and 8 ′ can therefore be accurately positioned by means of said corner-against-stopper positioning. The accuracy of said positioning is further enhanced by the fact that the sum of the respective lengths of segments 13 and 13 ′ equals the width of said recess.
[0029] Silencing apparatus as shown in FIGS. 1 and 2 are not symmetrical. According to an alternative embodiment of a silencing apparatus according to the present invention. said silencing apparatus as shown in FIGS. 1 and 2 could be symmetrical. Moreover. said silencing apparatus as shown in FIGS. 1 and 2 may be used with air flowing in either direction, in the case of the non-symmetrical embodiments.
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A silencing apparatus to be fitted between a first air or fluid intake duct ( 1 ) and a second air or fluid exhaust duct ( 2 ), said silencing apparatus being notably fitted between an engine turbine and a thermal exchanger and including a cylindrical main hollow body ( 3 ), a cylindrical input connection ( 4 ) and a cylindrical output connection ( 4′ ) with one or a plurality of straight sections smaller than the straight section of said main body ( 3 ), and at least one partitioning part ( 8 ) defining with the internal surface of said main hollow body at least two toric chambers ( 9, 10 ).
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority from Provisional Application Ser. No. 61/162,725 filed on Mar. 24, 2009.
FIELD OF THE INVENTION
[0002] The present invention relates to liners for pipes or various other passageways. More specifically, this invention relates to liners for underground sewers which are used to repair broken, pitted, or leaking main sewer pipes, lateral sewer pipes and gas pipes. The invention is directed to cured in place liners which have a barrier layer which is resistant to migration of styrene. That is, the liners are cured inside the pipe to be repaired. The invention is also directed to cured in place liners which use a styrene based polyester thermoset resin saturated fabric where the thermoset resin is cured (hardened) by the use of heat.
BACKGROUND OF THE INVENTION
[0003] The cured in place method of lining damaged or broken pipes, such as sewers and gas pipes, has become a very successful method of repairing underground pipes. The method avoids the need, to excavate the underground pipe and the resulting damage to surface infrastructure, such as paved streets and buildings. The cured in place method involves first positioning the liner inside the pipe while the liner is in a flexible state, then curing the liner to a hard state within the pipe while forcing the liner against the inside of the damaged pipe. Conventional methods use air, steam or water to pressurize the liner to have the flexible liner conform to the inside of the pipe and cure the liner to a hard state while it is held by the pressure to the inside of the pipe.
[0004] The prior art liners have been made by using a fabric on one side of the liner and a single layer polymer sheet on the other side. The fabric is saturated with an uncured thermoset material, such as a styrene based polyester resin or epoxy resin. The curing, that is the process of converting the thermoset material to a rigid state, is performed after the liner has been placed inside the pipe. The liner can be placed in the pipe to be repaired by either the dragged-in method as described in U.S. Pat. No. 4,009,063 or the inversion method as described in U.S. Pat. No. 4,064,211, both of these patents are herein incorporated by reference. The polymer sheet placed on the fabric must be resistant to the thermosetting material used and also able to withstand the heat used to cure the thermoset material. Various thermoplastics and elastomers have been used to coat the fabrics, with polyurethane being frequently used. Thermoplastic polyurethane is particularly desirable because of its abrasion resistance, tear resistance and elastic properties.
[0005] One problem that occurs when using a styrene based polyester as the thermosetting resin is the migration of styrene from the resin and through the thermoplastic polymer layer coated on the resin absorbent material layer. The styrene enters the cavity of the cured in place pipe and contaminates the media, such as water or steam, used to pressurize the pipe liner. When the media is evacuated from the pipe, it must be specially processed because it is contaminated with styrene, rather than simply being diverted to the local city sewer system. Also, the styrene odor which must also be dealt with can be a problem.
[0006] It would be desirable to have a thermoplastic layer which would greatly reduce the styrene migration into the media used to pressurize the pipe liner and allow the media to be processed through normal sewer treatment facilities. Installation costs could be reduced and the environment could be improved by such a development.
SUMMARY OF THE INVENTION
[0007] A cured in place liner for a passageway or pipe comprising a barrier layer to greatly reduce the migration of styrene through the liner. The liner has at least one layer of resin absorbent material, preferably a non-woven resin absorbent material. The liner also has a thermoset resin, preferably a styrene polyester resin, impregnated into the resin absorbent material layer. The liner has a thermoplastic coating attached to the resin absorbent material layer. The coating comprises a thermoplastic barrier layer, which is preferably either a high hardness thermoplastic polyurethane polymer or an ethylene vinyl alcohol polymer. The coating is preferably a three layer coating comprising (a) a first thermoplastic layer in contact with the resin absorbent material layer; (b) a second thermoplastic barrier layer in contact with the first thermoplastic layer and third thermoplastic layer; and (c) a third thermoplastic layer in contact with the barrier layer. The first and third layers of the coating can be made from a thermoplastic polymer selected from the group consisting of thermoplastic polyurethane (TPU), co-polyamide (COPA) and co-polyester (COPE).
[0008] In the most preferred embodiment, the resin absorbent material layer is a non woven polyester fabric, the thermoset resin is a styrene polyester resin, and the coating is a three layer coating having polyester thermoplastic polyurethane polymer (TPU) as the first and third layer and a barrier layer (second layer) of either high hardness TPU or ethylene vinyl alcohol (EVOH) polymer between the first and third layers.
DETAILED DESCRIPTION OF THE INVENTION
[0009] The cured in place liner for a passageway or pipe is comprised of: (a) at least one resin absorbent material layer; (b) a thermosettable resin absorbed into the resin absorbent material layer; and (c) a thermoplastic coating or film comprising a barrier material. Preferably, the thermoplastic coating is a three layer film having a first thermoplastic layer in contact with the resin absorbent material layer, a second thermoplastic barrier layer, and a third thermoplastic layer in contact with the barrier layer. The second thermoplastic barrier layer can be either a high hardness TPU or EVOH polymer. The first and third layers of the coating can be the same or different, and can be TPU, COPA or COPE polymers. An example of a co-polyamide (COPA) polymer is one commercially available as Pebax® from Arkema. An example of a co-polyester (COPE) polymer is one commercially available as Hytrel® from DuPont. The most preferred embodiment is to use TPU polymers for all three layers of the coating, with the first and third layer being low hardness TPU (less than 98 Shore A) and the second barrier layer being a TPU having high hardness (60 Shore D or greater). The barrier layer of high hardness TPU is disposed between the first and third layers of low hardness TPU. The invention will be described in terms of the most preferred embodiment of using TPU for all three layers of the coating. The coating in this specification means a film.
TPU for First and Third Layers of Coating
[0010] Thermoplastic polyurethane (TPU) polymers used for the first and third layers in this invention are made by reaction of three reactants. The first reactant is a hydroxyl terminated intermediate, such as a polyester, polyether, polycarbonate or mixtures thereof hydroxyl terminated intermediate. The second reactant is a glycol or amine chain extender with a glycol chain extender being preferred. The third reactant is an isocyanate, preferably a diisocyanate. Each of the preferred three reactants is discussed below.
[0011] The hydroxyl terminated polyester intermediate is generally a linear polyester having a number average molecular weight (Mn) of from about 1000 to about 10,000, desirably from about 2000 to about 5000, and preferably from about 2000 to about 3000. The molecular weight is determined by assay of the terminal functional groups and is related to the number average molecular weight. The hydroxyl terminated polyester intermediate preferably has a low acid number, such as less than 1.5, preferably less than 1.0 and more, preferably less than 0.8. A low acid number for the hydroxyl terminated polyester intermediate is preferred for liners which come in contact with moisture, because low acid numbers improve the hydrolytic stability of the TPU polymer. Acid number is determined according to ASTM D-4662 and is defined as the quantity of base, expressed in milligrams of potassium hydroxide that is required to titrate acidic constituents in 1.0 gram of sample. Hydrolytic stability can also be improved by adding hydrolytic stabilizers to the TPU which are known to those skilled in the art of formulating TPU polymers. The hydroxyl terminated polyester intermediates are produced by (1) an esterification reaction of one or more glycols with one or more dicarboxylic acids or anhydrides or (2) by transesterification reaction, i.e., the reaction of one or more glycols with esters of dicarboxylic acids. Mole ratios generally in excess of more than one mole of glycol to acid are preferred, so as to obtain linear chains having a preponderance of terminal hydroxyl groups. Suitable polyester intermediates also include various lactones such as polycaprolactone typically made from ε-caprolactone and a bifunctional initiator such as diethylene glycol. The dicarboxylic acids of the desired polyester can be aliphatic, cycloaliphatic, aromatic, or combinations thereof. Suitable dicarboxylic acids which may be used alone or in mixtures generally have a total of from 4 to 15 carbon atoms and include: succinic, glutaric, adipic, pimelic, suberic, azelaic, sebacic, dodecanedioic, isophthalic, terephthalic, cyclohexane dicarboxylic, and the like. Anhydrides of the above dicarboxylic acids such as phthalic anhydride, tetrahydrophthalic anhydride, or the like, can also be used. Adipic acid is the preferred acid. The glycols which are reacted to form a desirable polyester intermediate can be aliphatic, aromatic, or combinations thereof, and have a total of from 2 to 12carbon atoms, and include ethylene glycol, diethylene glycol, 1,2-propanediol, 1,3-propanediol, 1,3-butanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, 2,2-dimethyl-1,3-propanediol, 1,4-cyclohexanedimethanol, decamethylene glycol, dodecamethylene glycol, and the like, 1,4-butanediol is the preferred glycol. A blend of two or more glycols may be used. For a liner to be used to line a pipe where microbial resistance is required, such as gas pipes, diethylene glycol is the preferred glycol.
[0012] Suitable glycol chain extenders used as the second reactant to make the TPU polymer used in the first and third layers can be aliphatic, aromatic or combinations thereof and have from 2 to about 12 carbon atoms. Preferably, the glycol chain extenders are lower aliphatic or short chain glycols having from about 2 to about 10 carbon atoms and include, for instance, ethylene glycol, diethylene glycol, propylene glycol, dipropylene glycol, 1,4-butanediol, 1,6-hexanediol 1,3-butanediol, 1,5-pentanediol, 1,4-cyclohexanedimethanol hydroquinone, di(hydroxyethyl) ether, neopentyglycol, and the like, with 1,4-butanediol being preferred, Aromatic glycols can be used as the chain extender to make the TPU including benzene glycol and xylene glycol. Xylene glycol is a mixture of 1,4-di(hydroxymethyl) benzene and 1,2-di(hydroxymethyl) benzene. Benzene glycol specifically includes hydroquinone, i.e., bis (beta-hydroxyethyl) ether also known as 1,4-di(2-hydroxyethoxy) benzene; resorcinol, i.e., bis(beta-hydroxyethyl) ether also known as 1,3-di(2-hydroxyethyl) benzene; catechol, i.e., bis(beta-hydroxyethyl) ether also known as 1,2-di(2-hydroxyethoxy) benzene; and combinations thereof. A mixture of two or more glycols may be used as the chain extender in the TPU of this invention. A mixture of 1,4-butanediol and 1,6-hexanediol is the preferred mixture.
[0013] The third reactant to make the TPU for the first and third layers of this invention is a diisocyanate. Suitable diisocyanates include aromatic diisocyanates such as: 4,4′-methylenebis-(phenyl isocyanate) (MDI); m-xylylene diisocyanate (XDI), phenylene-1,4-diispcyanate, 1,5-naphthalene diisocyanate, diphenylmethane-3,3′-dimethoxy-4,4′-diisocyanate (TODI) and toluene diisocyanate (TDI); as well as aliphatic diisocyanates such as isophorone diisocyanate (IPDI),; 1,4-cyclohexyl diisocyanate (CHDI), decane-1,10-diisdcyariate, hexamethylene diisocyanate (HDI), and dicyclohexylmethane-4,4′-diisocyanate. The most preferred diisocyanate is 4,4′-methylenebis (phenyl isocyanate), i.e., MDI. A mixture of two or more diisocyanates can be used. Also, small amounts of isocyanates having a functionality greater than 2, such as triisocyanates can be used together with the diisocyanates. Large amounts of isocyanates with a functionality of 3 or more should be avoided as they will cause the TPU polymer to be crosslinked and thus interfere with its ability to be melt processed.
[0014] The three preferred reactants (hydroxyl terminated polyester intermediate, glycol chain extender, and diisocyanate) are reacted together to form the high molecular weight TPU used in the first and third layers of the TPU coating of this invention. Any known processes to react the three reactants may be used to make the TPU. The preferred process as a so-called one-shot process where all three reactants are added to an extruder reactor and reacted. The equivalent weight amount of the diisocyanate to the total equivalent weight amount of the hydroxyl containing components, that is, the hydroxyl terminated polyester intermediate arid the chain extender glycol, is from about 0.95 to about 1.10, desirably from about 0.96 to about 1.02, and preferably from about 0.97 to about 1.005. Reaction temperatures utilizing urethane catalyst are generally from about 175° C. to about 245° C. and preferably from 180° C. to 220° C.
[0015] Generally, any conventional catalyst can be utilized to react the diisocyanate with the polyester intermediates or the chain extender and the same is well known to the art and to the literature. Examples of suitable catalysts include, the various alkyl ethers or alkyl thiol ethers of bismuth or tin wherein the alkyl portion has from 1 to about 20 carbon atoms with specific examples including bismuth octoate, bismuth laurate, and the like. Preferred, catalysts include the various tin catalysts such as stannous octoate, dibutyltin dioctoate, dibutyltin dilaurate, and the like. The amount of such catalyst is generally small such as from about 20 to about 200 parts per million based upon the total weight of the polyurethane forming reactants.
[0016] The thermoplastic polyurethane can also be prepared utilizing a pre-polymer process. In the pre-polymer route, the hydroxyl terminated polyester intermediates are reacted with generally an equivalent excess of one or more diisocyanates to form a pre-polymer solution having free or unreacted diisocyanate therein. Reaction is generally carried out at temperatures of from about 80° C. to about 220° C. and preferably from about 150° C. to about 200° C. in the presence of a suitable urethane catalyst. Subsequently, a selective type of chain extender as noted above is added in an equivalent amount generally equal to the isocyanate end groups as well as to any free or unreacted diisocyanate compounds. The overall equivalent ratio of the total diisocyanate to the total equivalent of the hydroxyl terminated polyesters and the chain extender is thus from about 0.95 to about 1.10, desirably from about 0.96 to about 1.02 and preferably from about 0.97 to about 1.005. The equivalent ratio of the hydroxyl terminated polyesters to the chain extender is adjusted to give the desired shore hardness. The chain extension reaction temperature is generally from about 180° C. to about 250° C. with from about 200° C. to about 240° C. being preferred. Typically, the pre-polymer route can be carried out in any conventional device with an extruder being preferred. Thus, the polyester intermediates are reacted with an equivalent excess of a diisocyanate in a first portion of the extruder to form a pre-polymer solution and subsequently the chain extender is added at a downstream portion and reacted with the pre-polymer solution. Any conventional extruder can be utilized, with extruders equipped with barrier screws having a length to diameter ratio of at least 20 and preferably at least 25 are preferred.
[0017] Useful additives can be utilized in suitable amounts and include opacifying pigments, plasticizers, colorants, mineral fillers, stabilizers, lubricants, wax, UV absorbers, processing aids, and other additives as desired. Useful opacifying pigments include titanium dioxide, zinc oxide, and titanate yellow, while useful tinting pigments include carbon black, yellow oxides, brown oxides, raw and burnt sienna or umber, chromium oxide green, cadmium pigments, chromium pigments, and other mixed metal oxide and organic pigments. Useful fillers include diatomaceous earth (superfloss) clay, silica, talc, mica, wallostonite, barium sulfate, and calcium carbonate. If desired, useful stabilizers such as antioxidants can be used and include phenolic antioxidants, while useful photostabilizers include organic phosphates, and organotin thiolates (mercaptides). Useful lubricants include metal stearates, paraffin oils and amide waxes. Useful UV absorbers include 2-(2′-hydroxyphenol) benzotriazoles and 2-hydroxybenzophenones. Additives can also be used to improve the hydrolytic stability of the TPU polymer.
[0018] The weight average molecular weight (Mw) of the TPU polymer is generally about 60,000 to about 500,000 and preferably from about 80,000 to about 300,000 Daltons. For applications where steam is used to force the pipe liner against the wall of an existing pipe and to cure the thermosettable resin, the TPU polymer preferably has high temperature performance properties as exhibited by a DSC 2 nd heat melt endotherm peak temperature of greater than about 120° C. preferably greater than about 140° C. and more preferably less than about 180° C. This high temperature performance is necessary to prevent holes from forming in the liner during the cured in place installation. The temperature performance properties are measured using a Differential Scanning Calorimetry (DSC) using scan conditions from −100° C. to 230° C. in heat/cool/heat mode at 10° C./min. ASTMD-3418-03 standard describes the DSC test. The 2 nd heat melt endotherm peak temperature is used to correct for any variances in the sample.
[0019] The most preferred TPU polymers used in the first and third layers of the TPU liner will have a Shore A hardness of from about 85 A to about 98 A, preferably from 85 A to 95 A, and will have a Melt Flow Index of equal to or less than 80 g/10 min. @210° C. and 3.8 Kg load, preferably less than 65 g /10 min. and more preferably less than 50 g/10 min. Calendaring grades of TPU will typically have a Melt Flow Index of about 45 to 80 whereas extrusion grades will typically have a Melt Flow Index of 40 or less. Commercial TPU polymers that meet these requirements are known as Estane® TPU 58437, 58277, 58447, 54605, 54777, T5630, T5620, 58605 and X-1351 and are commercially available from Lubrizol Advanced Materials, Inc. TPU polymers having a hardness higher than 98 Shore A can be too stiff to facilitate the insertion of the liner into the damaged pipe in some applications, particularly by the inversion method. Shore A and Shore D hardness are determined according to ASTM D2240.
[0020] When the TPU is to be used for lining gas pipes, it is preferred to use a TPU which is made from a low acid number polyester intermediate and where the polyester intermediate is made by reacting adipic acid with diethylene glycol, as this type of TPU is believed to be more microbial resistant. Resistance to microbes is desirable for gas pipes. The type of TPU used can vary depending on the environment encountered in use and the temperature required for the curing process.
[0021] The TPU should also have good resistance to solvents. Solvents can be used to solvent-weld TPU patches over the holes drilled into the liner, which are made to facilitate getting the thermosettable resin into the resin absorbent layer. Solvents also can be used to solvent-weld a TPU tape over the lengthwise seams of the liner to make a closed tube from the original flat rectangular sheet.
Barrier Layer
[0022] A barrier layer (second layer) which is resistant to the migration of styrene is used between the first and third layers discussed above. The thermosetting resin used in the cured-in-place liner is usually a polyester resin which uses styrene to cure the resin. If styrene migrates through the thermoplastic portion of the liner, styrene can contaminate the water or steam used to inflate the liner. If too much styrene is present in the water or steam, the water must be collected and disposed of by more costly means, rather than discharged to a municipal drainage system.
[0023] It has been found that a styrene barrier layer can be formed from either a very hard TPU or from an ethylene vinyl alcohol (EVOH) polymer. The barrier layer is preferably placed between the first and third layers. The barrier layer does not have as good of adhesion to the resin absorbent material as the firsthand third layers, thus it is not placed directly onto the resin absorbent material, but rather is placed between the first and third layers. A suitable adhesive could be applied between the barrier layer and the resin absorbent material if it is desired to place the barrier layer directly onto the resin absorbent material.
[0024] The barrier layer, is preferably a very hard TPU, with a hardness of 60 Shore D or greater, preferably 65 Shore D or greater, more preferably 75 Shore D or greater, and most preferably about 85 Shore D or greater. The barrier layer, will be described more fully below for the preferred material of a very hard TPU.
[0025] The very hard rigid TPU polymer is made by reacting a polyisocyanate with a short chain diol (i.e., chain extender), and optionally less than 15 weight percent of polyol (hydroxyl terminated intermediate as is used in the first and third TPU layer described above). Preferably, the rigid TPU polymer contains less than 5 weight percent polyol, and more preferably zero polyol is present in the rigid very hard TPU polymer. The rigid very hard TPU polymer has a durometer hardness of 60 Shore D or greater, preferably 65 Shore D or greater, more preferably 75 Shore D or greater, and most preferably 85 Shore D or greater.
[0026] Suitable chain extenders to make the rigid very hard TPU polymer are preferably lower aliphatic or short chain glycols having from about 2 to about 12 carbon atoms and include for instance ethylene glycol, diethylene glycol, propylene glycol, dipropylene glycol, 1,4-butanediol,1,6-hexanediol, 1,3-butanediol, 1,5-pentanediol, 1,4-cyclohexanedimethanol hydroquinone di(hydroxyethyl) ether, neopehtyglycol, and the like as well as mixtures thereof, with 1,6-hexanediol being preferred. Other glycols, such as aromatic glycols could be used but are not preferred.
[0027] Suitable polyispcyanate to make the rigid very hard TPU polymer include aromatic diisocyahates such as 4,4′-methylenebis-(phenyl isocyanate) (MDI); m-xylene diisocyanate (XDI), phenylene-1,4-diisocyanate, naphthalene-1,5-diisocyanate, diphenylmethane-3,3′dimethoxy-4,4′-diisocyanate and toluene diisocyanate (TDI); as well as aliphatic diisocyanates such as isophorone diisocyanate (IPDI), 1,4-cyclohexyl diisocyanate (CHDI), decane-1,10-diisocyanate, and dicyclohexylmethane-4,4′-diisocyanate. The most preferred diisocyanate is 4,4′methylenebis(phenyl isocyanate), i.e., MDI.
[0028] Preferably, the rigid very hard TPU polymer is made by reacting the polyisocyanate shown above with the chain extender, without any polyol being present. If polyols are used, they should be used in small amounts of less than up to 15 weight percent, and more preferably less than 5 percent of the total TPU reactants. If used, the polyols, also known as hydroxyl terminated intermediates are used in very small amounts to increase impact strength. The polyols which can be used are any of the normal polyols used in making TPU polymers. These include hydroxyl terminated polyesters, hydroxyl terminated polyethers, and hydroxyl terminated polycarbonates. Preferred hydroxyl terminated intermediates are polymers described in more detail above in the description of the first and third TPU polymer layers.
[0029] The level of polyisocyanate preferably diisocyanate, used is the equivalent weight of diisocyanate to the equivalent weight of hydroxyl containing components (i.e., hydroxyl terminated intermediate, if used, and the chain extender glycol). The ratio of equivalent weight of polyisocyanate to hydroxyl containing components is from about 0.95 to about 1.10, and preferably from about 0.96 to about 1.02, and more preferably from about 0.97 to about 1.005.
[0030] The reactants to make the rigid very hard TPU polymer are reacted together in preferably a one-shot polymerization process, as is well known to those skilled in the art. The one-shot process, involves feeding the reactants to a heated twin screw extruder where the reactants are polymerized and the polymer is formed into pellets upon exiting the extruder.
[0031] Suitable rigid very hard TPU for the barrier layer is available commercially as Isoplast® and HS 85, both available from Lubrizol Advanced Materials, Inc. of Cleveland, Ohio, U.S.A.
Resin Absorbent Material
[0032] A resin absorbent material is used as one layer of the liner. The resin absorbent material is any material which absorbs or holds the thermosettable resin. The resin absorbent layer can be from 0.1 to 20 cm thick, preferably from 0.2 to 15 cm thick and more preferably from 0.3 to 10 cm thick. Suitable resin absorbent materials include fibrous materials of organic or inorganic fibers which may be woven or non-woven fibers. Preferably, the resin absorbent material is a needle punched non-woven material, such as polyester non-woven mat when lining sewers (main or lateral). For lining gas pipes, a glass fiber material is typically preferred.
[0033] The TPU polymer of the first layer described above is coated onto one side of the resin absorbent material. Melt processing equipment is used to coat the TPU onto the resin absorbent material. Suitable melt processing equipment includes calender and extrusion processes. The preferred thickness of the TPU coating layer (first layer) on the liner is from about 50 to about 1000 micrometers, preferably from about 100 to about 800 micrometers, and more preferably from about 100 to about 500 micrometers thick. The TPU coating layer (first layer) bonds very well to the polyester non-woven mat without the use of adhesives, thus the polyester non-woven mat is preferred with the TPU coating of this invention.
[0034] Often two layers of resin absorbent material are used where the cured-in place liner is designed for larger diameter pipes (such as greater than 25 cm diameter) in need of repair. For use in smaller pipes such as laterals, it is common practice to use a single layer of resin absorbent material.
[0035] The TPU coating is made up of three separate layers. The first layer of TPU is coated onto the resin absorbent layer. The second layer, barrier layer, is applied to the first layer and the third layer of TPU is applied to the second layer (barrier layer). The barrier layer should have a thickness of from about 12 micrometers (0.5 mil) to about 75 (3 mils) micrometers, and preferably from about 20 to about 30 micrometers. The barrier layer is very stiff when using a high hardness TPU, and therefore the thicker this layer, the more difficult it would be to install the liner inside a pipe. It has been found that when using a barrier layer of about 1 mil (25 micrometers), the liner can be installed by the inversion method in a pipe needing repair. Although the barrier layer could be thinner than that specified above and still function as a barrier, it is difficult to extrude or calender a film less than 12 micrometers thick. Since extrusion or calendering is the preferred method to produce the film for the barrier layer, it is recommended that a thickness of about 1 mil (25 micrometers) be used. The third TPU layer is placed on the barrier layer. The third TPU layer will have a thickness as described above for the first TPU layer (that is in contact with the resin absorbent layer). The most preferred TPU coating is a three layer TPU coating with the first and third layers each being about 100 micrometers in thickness, and the second layer (barrier) being about 25 micrometers in thickness.
[0036] The softer TPU in the first and third layer of the coating needs to be in contact with the resin absorbent layer to achieve good adhesion to the resin absorbent layer. The very hard TPU in the barrier layer does hot have as good adhesion to the resin absorbent layer as the softer TPU used in the first and third layers. Also, the softer TPU of the first and third layers needs to be on the outside layer of the liner, because it is more easier to patch the holes cut into the liner for the purpose of adding the thermoset resin and to glue the seam tape onto the liner to create a cylindrical shape of the liner from the original flat rectangular shape in which the liner is created. The very hard TPU barrier layer is not easy to solvent glue patches or tape to the hard TPU, thus the very hard TPU barrier layer should be sandwiched between two softer TPU layers.
Liner
[0037] To make the liner of this invention, the TPU is melt coated or extrusion coated onto the resin absorbent material. The first layer of softer TPU can be melt coated or extrusion coated onto the resin absorbent material. The third layer of softer TPU can be co-extruded with the very hard TPU barrier layer in a separate step and the combined third layer and barrier layer can be melt applied to the first TPU layer as it is being melt coated onto the resin absorbent material. The liner can also be made in one step by co-extruding or calendering all three layers of TPU as the three layers of TPU coating is applied to the resin absorbent material. A resin capable of being made into a thermoset resin, such as vinyl ester resin or polyester resin, which contains styrene, is added to the resin absorbent material. At this stage (before curing), the liner is flexible and can be placed inside the passageway of a cavity, such as a sewer pipe. The flexible liner can be inserted by either the drag-in or inversion method, which is well known in the art. Once inside the cavity, heat and pressure are added by injecting steam and/or hot water to force the liner against the inside of the pipe and to cure in place the thermoset resin. The liner can also be inserted into the cavity by use of hot water under pressure. Once the resin is cured, it becomes thermoset and the liner becomes rigid to form a rigid pipe within a pipe.
[0038] The liner can be made to the desired length required to repair the pipe, and preferably is a continuous tubular liner. The liner should have a length sufficient to repair the pipe with one continuous length that is not required to be spliced together from shorter pieces. The liner will typically be at least 50 meters in length and can be as long as 5000 meters in length. More typical the liners are lengths of from 200 to 1000 meters in length.
[0039] The diameter of the liner, once formed into a closed tube will vary depending on the diameter of pipe needing repair. Typical diameters are from about 5 cm to about 250 cm, but more commonly the diameters are 20 cm to about 150 cm.
[0040] The liner can conform to the shape of the inside of the pipe needing repair. The shape of the pipe does not need to be perfectly circular, but rather can be non-circular such as egg-shaped or elliptical shaped. The liner can also negotiate bends in the pipe.
[0041] After the resin absorbent fabric is impregnated with the thermosettable resin and the liner is made, it is typically stored at a cold temperature, either in an ice bath or a refrigerated truck. This cold storage is necessary to prevent premature curing of the thermoset resin, before it is installed. The liner can be brought to the job site in the refrigerated truck to prevent premature curing of the resin.
[0042] After the liner is inserted into the damaged pipe, the resin is cured by exposing the liner to an elevated temperature of usually about 80° C. to 100° C. for 3 to 12 hours. Steam, curing requires less time, usually 3-5 hours as compared to hot water which usually takes 8-12 hours.
[0043] The invention will be better understood by reference to the following example.
EXAMPLES
[0044] The Examples are presented to show the improved resistance to styrene permeability of the coating materials of this invention. Examples 1 and 2 are comparative examples where TPU films normally used in cured-in-place pipe liners are evaluated. Examples 3, 4 and 5 are examples of this invention.
[0045] The films were evaluated for styrene permeability according to ASTM D814 Inverted Cup Permeability test. The results for styrene permeability are expressed in grams/square meter/day.
[0046] Example 1 (comparative) uses a 5 mil thick (127 micrometers) film of a 93 A Shore hardness TPU made from a polyester polyol (adipic acid+1,4-butanediol), 1,4-butanediol chain extender, and MDI. Example 2 (comparative) uses a 5 mil thick (127 micrometers) film of a 95 A Shore hardness TPU made from a polyester polyol (adipic acid+diethylene glycol), 1,4-butanediol chain extender and MDI. Example 3 uses a 5 mil thick (127 micrometers) film of a 62 D Shore hardness TPU made, from a polyester polyol (adipic acid+diethylene glycol), 1,4-butanediol chain extender and MDI. Example 4 uses a co-extruded 5 mil thick (127 micrometers) film which is made up of 1 mil thick (25.4 micrometers) of a 85 Shore D hardness TPU made from chain extender and MDI (no polyol) and 4 mil thick (101.6 micrometers) film of the 93 A Shore hardness TPU used in Example 1. Example 5 uses a co-extruded 5 mil thick (127 micrometers) film which is made up of 1 mil thick (25.4 micrometers) film of EVOH and 4 mil thick (101.6 micrometers) film of the TPU used in Example 1.
[0047] The results for styrene permeability of the five films for Examples 1-5 and if the film has sufficient flexibility to be used in a cured-in-place pipe liner while using the inversion method of installation are shown in Table 1 below:
[0000]
ASTM D814 Styrene
Example
Film Flexibility
Permeability (g/m 2 /day
1
YES
4800
2
YES
1800
3
NO
190
4
YES
29
5
YES
2.3
[0048] As can be seen from the results the styrene permeability is greatly reduced when using a very hard (85 Shore D) TPU at a 1 mil thickness together with a soft (93 Shore A) TPU at 4 mils thickness. Also, the co-extruded film using EVOH as the 1 mil barrier layer (Example 5) shows greatly reduced styrene permeability.
[0049] While in accordance with the Patent Statutes, the best mode and preferred embodiment has been set forth, the scope of the invention is not limited thereto, but rather by the scope of the attached claims.
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A liner for repairing damaged pipes, such as underground sewer or gas pipes is disclosed. The liner comprises a TPU coating on fibrous mat of non-woven fabric. The TPU coating contains a barrier layer to retard the migration of styrene from the liner to the media used to force the liner against the damaged pipe and to activate the thermoset resin. The thermoset resin converts the liner from a flexible state to a rigid state as the liner is cured in place inside the pipe.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. patent application Ser. No. 10/861,847, filed Jun. 4, 2004.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to the field of printed circuit fabrication, and more particularly to an improved plating buss on a substrate such as for example a printed circuit board (PCB), which addresses manufacturing variations and alignment problems associated with PCB singulation for improved board yield.
[0003] Basically, a printed circuit board consists of a sheet of rigid insulating substrate such as phenolic, glass impregnated epoxy or the like, having a pre-defined pattern of thin metallic—usually copper—foil conductive paths (so-called “traces”) appearing on one or both sides of the substrate. These traces collectively define all the electrical interconnections among all the components and are routed between appropriate locations on the board.
[0004] Electrolytic plating is one method used to improve electrical conductivity and/or wire bondability in the trace termination areas provided on a multi-layered printed circuit board (PCB). Generally, a panel populated with an array of PCBs is connected to one terminal of either a d.c. or a pulsed plating voltage source and placed in an electrolyte in order to be plated. A metal to be deposited is then connected to the other terminal and similarly immersed in the electrolyte. The transfer of the metal is accomplished via the ions contained in the current flowing between the metal and the panel.
[0005] Since electroplating of metals requires that all sites on the panel to be plated must be electrically connected to the plating bath, one prior art method electrically connects the traces to a common straight-line plating buss (also known as a “tie” or “commoning” bar) for convenience. The straight-line plating buss is then used to provide the current during the plating process. However, a plating buss serves no useful function after the electroplating process. Thus, for improved process efficiency, prior art methods have provided the straight-line plating buss centered between adjacent PCBs defined on the panel, such that during a PCB singulation stage, the straight-line plating buss gets cut away.
[0006] PCB singulation is the process of taking a finished panel, and separating or depaneling the plurality of PCBs formed thereon into individual PCBs for a subsequent packaging process. One method of PCB singulation is to use a dicing saw. The panel is mounted on a saw carrier, mechanically, adhesively or otherwise, as known in the art. The saw carrier is then mounted on a stage of the dicing saw. Typically, the PCBs are arranged in rows and columns on the panel with the periphery of each PCB being rectangular. During the dicing process, the panel is sawn or diced with a rotating blade along a street lying between each of the rows and columns thereof.
[0007] Once all cuts associated with mutually parallel streets having one orientation are complete, either the blade is rotated 90° relative to the panel or the panel is rotated 90°, and cuts are made through streets in a direction perpendicular to the initial direction of cut. Since each PCB on a conventional panel has the same size and rectangular configuration, each pass of the saw blade is incrementally indexed one unit (a unit being equal to the distance from one street to the next) in a particular orientation of the panel. As such, the saw and the software controlling it are designed to provide uniform and precise indexing in fixed increments across the surface of the panel.
[0008] As mentioned previously above, PCB singulation is also used to remove process remnants, such as straight-line plating busses used in the (post formation) plating process of the PCBs. An illustration of one prior art plating buss is shown in FIG. 1 , wherein a PCB panel 100 has a plurality of traces 102 formed thereon by electrodeposition, which are connected by an associated straight-line plating buss 104 . At the PCB singulation stage, a saw blade dices the panel 100 along a cut, which removes panel material between parallel lines 106 and 108 in order to separate adjacent PCB segments 110 . If the cut is properly aligned, parallel lines 106 and 108 will flank a street 112 defined between the adjacent PCB segments 112 in order to also remove the straight-line plating buss 104 which was formed there along. As can be imaged, dicing the panel along the street 112 will thereby disconnect the associated traces 102 . According the width on the straight-line plating buss 104 can be considered as the “process window” for the PCB singulation stage.
[0009] However, over time, the blade and/or stage of the dicing saw may experience drift due to indexing errors of its drive motor and associated gearing. Additionally, variations in the PCB manufacturing process effecting PCB sizes and street locations, and variations in blade width due to uneven heating and wear can also result in indexing errors. Such indexing errors result potentially in the location of cut, illustrated by parallel lines 106 and 108 , moving off the street 112 and out of the process window. As illustrated by FIG. 2 , moving off the street 112 creates the potential for shorted circuits due to the cut failing to remove the straight-line plating buss 104 connecting the traces 102 in one of the adjacent PCB segments 110 . This circumstance decreasing board yield by rejecting PCBs with shorted traces even though all other features on each PCB may be good.
SUMMARY OF THE INVENTION
[0010] In view of the foregoing considerations, the present invention is directed to an improved plating buss, wherein the plating buss connecting traces of adjacent printed circuit board (PCB) in a substrate panel are provided in a serpentine design. The serpentine plating buss widens the PCB singulation process window, thereby minimizing short circuit problems often seen in PCB singulation due to indexing errors resulting from occasional manufacturing variations and alignment problems. Accordingly, the serpentine plating buss of the present invention increases board yield. Another benefit of the serpentine plating buss is that the sawn edge of each finished PCB may be improved due to the fact that no longer must PCB singulation be directly on top of the entire plating buss in order to disconnect joined conductive traces.
[0011] In one embodiment, a substrate panel containing a plurality of printed circuit boards is disclosed. The substrate panel comprises a plurality of conductive traces provided on the substrate, and a serpentine plating buss interconnecting the plurality of conductive traces and provided between adjacent ones of the plurality of printed circuit boards.
[0012] In another embodiment, a method for manufacturing a printed circuit is disclosed. The method comprises providing a substrate panel, providing a plurality of printed circuit boards on the substrate, the printed circuit boards having a plurality of conductive traces provided on the substrate, and interconnecting the plurality of conductive traces with a serpentine plating buss provided on the substrate between adjacent ones of the plurality of printed circuit boards.
[0013] In another embodiment, a method for manufacturing a printed circuit is disclosed. The method comprises providing a substrate having at least a pair of adjacent segments, the substrate having a conductive serpentine plating buss interconnecting conductive traces of the pair of adjacent segments, and singulating the substrate, the singulation removing a portion of the serpentine plating buss which disconnects the conductive traces.
[0014] In still another embodiment, a method for manufacturing a printed circuit board is disclosed comprising providing an unclad laminated substrate panel used for forming a plurality of printed circuit boards, associating an image of a desired circuitry pattern with the panel, the image comprises various circuitry traces interconnected by a serpentine plate buss, and developing the panel, wherein the desired circuitry pattern is defined on the panel.
[0015] These and other features and objects of the present invention will be apparent in light of the description of the invention embodied herein.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0016] FIG. 1 is a top elevation of a portion of a substrate panel bearing conductive traces connected by a prior art straight-line plating buss, and illustrating the alignment of a singulation cut having no indexing error which will result in no shorted traces;
[0017] FIG. 2 is a top elevation of a portion of a substrate panel bearing conductive traces connected by a prior art straight-line plating buss, and illustrating the alignment of a singulation cut having an indexing error which will result in shorted traces;
[0018] FIGS. 3 a - 3 d are side section views of a substrate panel showing a step-by-step explanation of a printed circuit manufacturing technique used to form the plating buss of the present invention;
[0019] FIG. 4 is a top elevation of a portion of a substrate panel bearing conductive traces connected by a plating buss according to the present invention, illustrating the alignment of a singulation cut having no indexing error which will result in no shorted traces;
[0020] FIG. 5 is a top elevation of a portion of a substrate panel bearing conductive traces connected by a plating buss according to the present invention, illustrating the alignment of a singulation cut having an indexing error which will result still in no shorted traces;
[0021] FIGS. 6 a - 6 c are illustrations of various serpentine plating buss embodiments according to the present invention.
[0022] In the drawings, dimensions of materials have been modified for clarity of illustration and are not necessarily true to scale.
DETAILED DESCRIPTION OF THE INVENTION
[0023] FIGS. 3 a - 3 d provides a step-by-step explanation of a printed circuit manufacturing technique used to form a plating buss according to the present invention. In conjunction with this explanation, FIGS. 4 and 5 each present a top elevation of a substrate panel having a plurality of adjacent printed circuit boards (PCBs) thereon and bearing conductive traces connected by a plating buss according to the present invention. FIGS. 6 a - 6 c are illustrations of various serpentine plating buss embodiments according to the present invention.
[0024] With reference to FIG. 3 a, manufacturing of a plurality of PCBs 10 begins similar to most other commonly used additive techniques. Namely, an unclad laminated substrate panel 12 used for forming the plurality of PCBs 10 is first provided. The panel 12 is normally made of a nonconductive material, such as phenolic, glass-impregnated epoxy, polymide, FR4, FR5 or the like. The panel 12 is then drilled in accordance with a predetermined pattern, such as by a C-N-C drilling machine. In particular, variously sized holes 14 are imparted through the panel 12 at a variety of locations, in the exact configuration of a desired hole pattern for each printed circuit. For ease of illustration, FIGS. 4 and 5 do not show any of the holes 14 .
[0025] The panel 12 is then coated with an activating layer 16 which promotes the adhesion of a conductive material, such as copper, to the unclad laminant panel 12 . Following coating, an outer surface of the activating layer 16 is coated with a resist material 18 as illustrated by FIG. 3 b. The resist material 18 is preferably a photopolymer plating resist solution well-known in the art, and is normally light sensitive.
[0026] A photographic film image or artwork 20 of a desired circuitry pattern 22 is then associated with the panel 12 . In particular, the artwork 20 provides a picture or image of various circuitry traces and is properly designed to selectively prevent light from passing through portions of the film. For example, with one well-known technique, the circuitry pattern is presented on the film in the form of an emulsion material which prevents the passage of light. The remainder of the film, where no circuitry is desired, is clear. A maskless, fully digital process, such as for example, a Digital Micromirror Device (DMD) or Gradient Light Valve (GLV) imaging system, may also be used to project a negative of the desired circuitry pattern 22 , onto the panel 12 as is known in the art.
[0027] The desired circuitry pattern 22 includes a serpentine plating buss design according to the present invention, which connects together a plurality of traces. One embodiment of the serpentine plating buss 24 is illustrated by FIGS. 4 and 5 , which connects a plurality of traces 26 in an “accordion” fashion. It is to be appreciated that the plating buss design of the present invention need not be continuous, equally sized, accordion shaped, or rectangular in dimension. For example, as illustrated by FIGS. 6 a - c, the serpentine plating buss of the present invention may be a saw toothed pattern 40 , a triangular pattern 42 , a curvilinear pattern 44 , or combinations thereof. A discussion of the advantages of having such a serpentine plating buss according to the present invention is provided in a later section.
[0028] Referring back to FIG. 3 b, with the artwork 20 in place, the panel 12 is then “exposed” to ultraviolet light 28 . As previously described, the artwork 20 is designed to selectively allow and/or prevent passage of the ultraviolet light 28 at desired locations. The resist material 18 is normally configured to “cure,” harden or otherwise react in response to exposure to ultraviolet light such that it is impervious to developer chemistry. At locations on the panel 12 where ultraviolet light is prevented from reaching the resist material 18 (i.e., the desired circuitry pattern), the resist material 18 will not cure, such that it will be attacked by developer chemistry.
[0029] The panel 12 is then “developed”. With this commonly-used technique, any resist material 18 not cured during exposure is removed from the panel 12 . As illustrated by FIG. 3 c, only cured portions of the resist material 18 remain on the panel 12 . Following developing, the desired circuitry pattern 22 having the design of the serpentine plating buss 24 is defined on the panel 12 . In particular and at this stage, the circuitry pattern 22 is defined by the activating layer 16 not otherwise covered by the resist material 18 .
[0030] The panel 12 is then processed through an energized plating bath 30 to deposit an electrolytic material layer, such as metals or precious metals like copper, silver, gold, platinum, nickel, tin, and the likes, onto the desired circuitry pattern 22 . During the electroplating process, the resist material 18 resists or shields the electrolytic material from plating to certain areas of the panel 12 , wherein the electroplated material is deposited only on exposed portions of the activating layer 16 . In this manner, only the desired circuitry pattern 22 receives the electroplated material. The panel 12 is then passed to additional (post plating buss formation) electroplating processes, wherein the formed plating busses 24 are then used to make electrical contact for improved electrical conductivity and/or wire bondability in termination (e.g. “trace”) areas of each of the printed circuit board 10 provided on panel 12 .
[0031] After plating, panel 12 is then subjected to a “stripping” process. During the stripping process, the resist material 18 is removed, leaving the plated material layer 32 and other optional electroplated material layers (not shown) as illustrated by FIG. 3 d. The plated material layer 32 is provided on the panel 12 in the desired circuitry pattern 22 which includes the serpentine plating buss, such as for example, the accordion plating buss 24 illustrated by FIGS. 3 and 4 , or one of the plating busses illustrated by FIGS. 6 a - 6 c. After stripping, the panel 12 is then singulated into individual PCBs 10 .
[0032] With refer to FIG. 3 , a conventional saw blade is employed at the PCB singulation stage. If there is no indexing errors, the saw blade will remove the material of the panel located between parallel lines 34 and 36 as a cut is made along a street 38 . As can be imaged, making such a cut will separate the adjacent boards 10 and remove a portion of the serpentine plating buss 24 , which disconnects the associated traces 26 . Since the design of the serpentine plating buss 24 zigzags over the street 38 , the entire plating buss need not be removed in order to disconnect the traces, unlike the straight-line plating buss shown in FIGS. 1 and 2 .
[0033] It is also to be appreciated that the “process window” defined by the serpentine plating buss 24 is larger than the prior art straight-line plating buss shown in FIGS. 1 and 2 . In this manner, even if over time, indexing errors result in the cut moving from the center of the street 38 , the saw blade will still remove a portion of the serpentine plating buss 24 and disconnect the traces 26 in both adjacent boards 10 , such as illustrated by FIG. 4 . Accordingly, board yield is increased as fewer PCBs are rejected with shorted traces. In one embodiment, a panel 12 provided with the serpentine plating buss of the present invention enlarges the PCB singulation process window to greater or equal to about ±0.165 mm from centerline of the street, as compared to a prior art process windows of less than or equal to about ±0.085 mm from centerline of the street. It is to be appreciated that the process window of the present invention is solely dependent upon the width of the serpentine pattern, whereas the prior art process window is dependent on saw blade width, buss line width, positional accuracy of the saw blade, and positional accuracy of the buss to the fixing feature.
[0034] Although the additive method was described in the formation of the plating buss of the present invention, those skilled in the art recognize that the subtractive method of forming a PCB may also be used. For example, in the subtractive method, a plurality of boards defined by a substrate is provided having at least one surface coated with a conductive material, such as a metal like copper. The circuitry pattern including an embodiment of a plating buss design according to the present invention is then printed onto the conducive material-coated surface of the board by a resist material. The remaining exposed conductive material-coated surface is etched away, and the resist is then removed leaving conductive circuitry having the serpentine plating buss of the present invention interconnecting conductive traces and adjacent PCB segments.
[0035] Additionally, although dicing was described as a suitable method for PCB singulation, the plating buss according to the present is also beneficial to panel subjected to other PCB singulation methods, such as for example, punching or stamping.
[0036] Thus, while certain representative embodiments and details have been shown for purposes of illustrating the invention, it will be apparent to those skilled in the art that various changes in the invention disclosed herein may be made without departing from the scope of the invention, which is defined in the appended claims.
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The present invention relates generally to a plating buss design and method for minimizing short circuit problems in PCB panel singulation. More particularly, the invention encompasses a serpentine plating buss which increases the PCB singulation process window thereby minimizing short circuit problems due to indexing errors caused by occasional manufacturing and equipment alignment problems. The serpentine plating buss design therefore increases board yield.
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ORIGIN OF THE INVENTION
Portions of this invention were made with Government support under award number ISI-8860547 awarded by the National Science Foundation. Accordingly, the Government has certain rights in this invention.
FIELD OF THE INVENTION
This invention relates generally to motion detection systems and relates specifically to a system for detecting motion of a moored ship through six degrees of freedom to facilitate accurate positioning and automatic loading/unloading of containerized cargo, from a dock onto a ship, by a crane system.
BACKGROUND OF THE INVENTION
The use of modern container ships to transport containerized cargo has become one of the primary means for shipping numerous types of cargo. Standard size containers and automatically operated crane systems substantially increase the productivity while reducing the manpower required and hazards incurred in loading and unloading freight transporting ships. Complete automatic loading and unloading of containers to and from a specific position on the ship is impeded by motion of the ship relative to the pier/crane. This motion is the result of winds, shifting tides, movement of the ship due to the addition of or removal of each container, and the like. Ship motion during and between loading or unloading of successive containers is sufficient to prevent complete automatic and exact placement of containers without tracking the ships position. At present, some fine adjustment of each container position is usually required by the crane operator due to the ship's motion. This additional adjustment is a time consuming, hazardous and costly task that can be improved if the crane were automated to compensate for ship motion.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a system for improving automation of the process of loading and unloading container ships.
Another object of the present invention is to provide a sensor system for predicting the position, orientation and motion of a ship with sufficient accuracy to enable the controlling device of a crane to automatically compensate for these variables and in order to place a container at the specified location on the ship.
A further object of the present invention is to provide a sensor and processing system that can accurately and instantaneously determine the exact position of a container ship relative to a fixed pier.
An additional object of the present invention is a motion detection system for accurately determining the exact position of a moored ship during a loading and unloading operation.
According to the present invention, the foregoing and additional objects are attained by providing a container loading crane on a fixed dock in position to load and unload containerized cargo onto, or off, a moored container ship. A sensor system, including three ultrasonic range finders and a CCD video camera, are mounted on the shipboard side of the container loading crane structure. Two of the range finders are mounted near the bottom of the crane structure while the third range finder is mounted approximately six feet above the pier surface. The video camera is also mounted on the crane structure and facing the side of the ship.
The ultrasonic range finders provide direct measurement of the distance of the ship from the pier with one-eighth inch resolution at the maximum distance from the crane to the ship. The video processor provides direct measurement of the height, fore-and-aft position, and pitch of the ship, and indirect measurement of the ship roll. Automatic focusing of the video lens onto a designated area of approximately three feet square at the minimum range from the crane to the ship is required. Each of the ultrasonic range finders and the video camera is provided with a temperature controlled all weather enclosure and affixed to the crane structure on a vibration-free mount. The system is designed to be all-weather however, processing of the video data must include reliability testing to ensure that in unusually low visibility weather, such as dense fog or heavy snowfall, the processor notifies the crane operator that manual control is required.
In the normal operation of the sensor system of the present invention, the initialization of values of ship position and orientation relative to the crane are determined by external means. Following this initialization, the sensor system provides all updated information. The estimated values for the ship position are obtained between each loading or unloading operation and these values are sent to the crane processor. These estimated values are converted by the processor into an estimated position for the next container, along with an estimate of the error in that prediction. The next container can then be quickly and automatically moved to that precise spot with the state vector being continually updated to adjust for additional ship motion.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the invention and many of the attendant advantages thereof will be more readily apparent as the same becomes better understood with reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
FIG. 1 is a schematic representation of an exemplary crane disposed on a fixed pier in position to load/unload a container ship and employing the motion determination system of the present invention;
FIG. 2 is a part schematic representation of a portion of the assembly shown in FIG. 1 and illustrating the top view of the crane support structure adjacent the dock side of the pier shown in FIG. 1 and illustrating the location of the ship motion and position sensors disposed thereon;
FIG. 3 is a part sectional, part schematic rear view of the structure shown in FIG. 2 and further illustrating the position relationship of the container ship and the ship motion and position sensors disposed on the crane structure;
FIG. 4 is a part schematic side view of the structure shown in FIGS. 2 and 3 further illustrating the position relationship of the container ship and the ship motion and position sensors according to the present invention;
FIG. 5 is a schematic flow diagram illustrating the necessary interfaces for data flow and sensor and information process of the present invention;
FIG. 6 is a part schematic view of the video camera housing employed in the present invention;
FIG. 7 is a view similar to FIG. 6 with parts broken away and schematically showing the components housed within the camera housing; and
FIG. 8 is a schematic diagram of the coordinate system employed in the ship motion determination according to the present invention.
DETAILED DESCRIPTION
Referring now to the drawings and more particularly to FIG. 1, there is shown a schematic side view of an exemplary crane assembly employing the present invention, and designated generally by reference numeral 10. Crane 10 is disposed on a fixed pier, or dock, 12 and adapted to load/unload containerized cargo on container ship 11. Crane 10 is provided with vertical supporting structures partially visible in this FIG and designated by reference numerals 13 and 14. Vertical support structures 13,14 serve to support horizontal arms or girders 15 and 16. Suitable wheels (not designated) are provided at the base of vertical support structures 13,14 to permit unrestricted crane travel about dock 12. Alternatively, the wheels of crane 10 may be disposed on tracks (not shown) to limit movement of crane 10 along the track, in a conventional manner. A wheeled carriage or trolley 17 is movable along a track 18 disposed on horizontal arm 15. An electrically operated crane motor is housed within crane motor housing 20 disposed on grider 15, as will be further explained hereinafter.
During operation, the crane operator rides in the cab of trolley 17 and maintains visual contact with hoist attachment device 21. Hoist attachment device 21 includes a spreader mechanism 22 that attaches, via conventional twist lock mechanism, to all four corners of an individual freight container 24. Containers 24 are of two basic sizes, each essentially eight feet wide and either slightly less than twenty feet, or slightly less than forty feet, long. The vertical position of spreader mechanism 22 is controlled by a series of crossing cables or ropes, some of which are shown in FIG. 1 and designated by reference numeral 23. Ropes 23 pass through blocks on trolley 17 and connect with suitable winches (not shown).
In operation, the crane operator in trolley 17 picks up a container 24 that has been positioned on platform 26 for loading onto container ship 11. In automated crane systems, the containers may also be stacked on the pier or taken directly from the truck chassis bed. When employing separate platform 26 on crane 10, a separate hoist mechanism 25 is also employed to first remove individual containers 24 from a truck 40 onto crane platform 26 and then each container is lifted from platform 26 to its destination on board the ship. These two steps are carried out by two entirely different hoist mechanisms 21,25 and under the supervision of two different operators.
The initial process of attaching the spreader of hoist mechanism 25 to container 24 on the pier, or on a truck 40, is manually intensive however, from the time the container reaches a height of eighteen feet on platform 26, the procedure may be automated. The operator of trolley 17 lifts container 24 high enough to clear the side of ship 11 and any containers already loaded above the deck, while running trolley 17 out arm 15 for automatic positioning of the spreader 22 and attached container 24 directly above its destination.
If ship 11 were to remain completely stationary, automated crane operation would be much easier to accomplish. However, due to winds, tides, shifting weight after each container is loaded or unloaded, and other factors, moored ships are, with little exception, subject to motion. This motion is adequate to prevent full automation of the loading process without tracking and compensating for that motion. It has been observed that ship motion during the intervals between periods of loading are considerably less pronounced to thereby indicate that the loading process might be the major contributor to observed ship motion. To accurately measure and compensate for this ship motion, a set of three ultrasonic range finders are secured to crane vertical support 13, facing ship 11, and disposed in a triangular pattern. Two of these range finders are visible in FIG. 1 and designated by reference numerals 27 (r 1 ) and 28 (r 2 ). The third range finder 29 (r 3 ) is illustrated more clearly in FIGS. 2 and 3. Range finders 27 and 29 are essentially parallel with the surface of pier 12 and are mounted near the bottom, and on separate spaced legs, of vertical support 13. Range finder 28 is vertically spaced from, and mounted on the same leg of vertical support 13 as, range finder 27. A video camera 30 is also mounted on vertical support 13 and faces the side of container ship 11.
FIG. 2 illustrates the ultrasonic range finders 28,29 and video camera 30 relative to container ship 11, as seen looking from the top of crane vertical support 13. Range finder 27 is obscured from view in this FIG by range finder 28.
FIG. 3 is a partial rear view of the crane 10 looking toward container ship 11 and illustrates a video target 35 on ship 11. The position of range finders 27,28 and 29, as disposed on the legs of vertical supports 13, are also illustrated in this FIG.
FIG. 4 is similar to FIG. 1 and more clearly illustrates the position of video camera 30 and range finders 27,28 relative to container ship 11. Range finder 29 is obscured from view in this FIG by range finder 27.
The data flow structure and processing units necessary for sensor input and tracking computations and updates for ship motion determination are illustrated in the schematic diagram of FIG. 5. As shown therein, range data from sensors 27,28 and 29 and pixel responses from video camera/processor 30 are transmitted to a sensor processor 35. Sensor processor 35 combines this data with container position data received through a loading processor 36 from a process controller 37 disposed on crane 10. All of this data is then combined with estimated ship position data received from loading processor 36 to derive a "corrected ship position" that is fed into the crane controls through process controller 37 for accurate positioning of a container 24 relative to the actual position of the ship 11 by crane within one inch 90% of the time and within 2.7 inches all of the time 10.
All processor controls are supervised by an operator positioned in process control housing 32 located at the base of crane 10. The automatic crane controls are capable of being manually overridden, when deemed necessary, by the crane operator in trolley 17. A conventional electrical power supply (not shown) is employed for the crane motor and other electrical components with an emergency back-up battery system utilized when needed. The power supply and electrical connections are not shown or further described herein in the interest of clarity and brevity.
Referring now more particularly to FIGS. 6 and 7, the details of video camera unit 30 will now be described. The exterior housing 43 is designed to be weather proof and vibration free and is constructed of a suitable plastics, such as Lexan or equivalent. Housing 43 must meet NEMA/ASTM standards for environmental protection and is certified, to at least one atmosphere, completely waterproof. A closure lock 44 is provided on one side of housing 43 and, when unlocked, permits removal of this entire side to permit access to the interior of the housing. Suitable O-ring gasket seals (not shown), provided between the contacting surfaces of the housing side and the remainder of the housing, ensure waterproof sealing of the housing when closed.
The front of housing 43 is provided with a sliding closure gate 45 for selectively exposing lens 48 of camera 30. A low voltage heater 50 and a Type J thermocouple 51 are electrically connected, via cannon type connector fitting 52 extending through housing 43, to a suitable electric supply (not shown). A suitable desiccant 55 is also provided within housing 43 for internal moisture control. A metal backing plate (not shown) for housing 43 is countersunk within the base wall portion to provide suitable tripod mounting of the instrument. Housing 43 is mounted on the crane base as indicated with the conventional mounting structure not illustrated in the interest of clarity. Housing 43 is mounted on crane support 13 with an adjustable aiming angle of 30 to 60 degrees, as indicated.
Similar environmental protection housings are provided for each of the ultrasonic range finders 27, 28, 29. Commercially available Icolete and Helix housings are suitable for practice of the present invention. Also, suitable shade protection is provided on crane vertical support 13 to shade each of the housed units 27, 28, 29 and 30 from direct exposure to the sun and precipitation.
A mathematical model for the ship motion wherein the observations of ultrasonic range finders 27,28 and 29 and video CCD 30 are integrated to update the position of ship 11 has been developed. In this process, fundamental concepts include
(1) The State Vector x describes the true ship position and motion;
(2) The Estimated State Vector e is the sensor system determination of x;
(3) The Observation Model infers e from the sensor observations; and
(4) The Motion Model predicts a state vector p at some future time, given e.
Assuming the ship to be a rigid object, the ship position and orientation with respect to the pier can be described completely by a six-state vector as illustrated in the coordinate system of FIG. 8. In this illustration x,y,z are chosen the coordinates of any point in space, where the x-axis is perpendicular to the pier, the y-axis is oriented parallel to the pier, and the z-axis is vertical, and where the origin is a fixed point on the pier, near the base of the crane. Then the position of the ship is given by a vector (x O ,y O ,z O ,θ X ,θ Y θ Z ) T , where x O ,y O ,z O is the position of a fixed point on the ship, and θ X ,θ Y ,θ Z are angles of pitch, roll, and heading (relative to the x-y- and z-axis), respectively. The ultrasound range finders are located at (O,O,O), (O,O,a), and (O,b,O), while the video camera is at any position in the y-z plane.
Because the process is re-initialized for each row of containers, the reference point (x O ,y O ,z O ) may be taken to be the midpoint of the current container row, i.e., y O is at the middle of the crane, x O is the distance of the midline of the ship from the crane, and z O is the height of the nominal center of gravity of the ship. The choice of these values instead of the center of gravity (CG) is motivated by the following considerations: (1) The exact position of the CG is not known, and changes somewhat with each container loaded or unloaded. These changes are highly nonlinear and difficult to predict. (2) If the ship point is fixed (x O ,y O ,z O ), the major reason for using a nominal CG is that the ship presumably rotates about that point, or nearly. In fact, observations indicate that the ship is always pressed against the pier at at least one point, and restrained in its motion by at least six hawsers with automatic tensioning devices, so it is very unlikely that the pivot point of the yaw (change in heading) component is near the CG. Pitch might still be centered near the CG, but observed changes in pitch are insignificantly small, so little error is induced by assuming the ship rotates on the row of containers being loaded. The one significant angular change is roll, and that fact necessitates using a point on the midline, near the CG height. (3) The purpose of the state vector estimate is to indicate the precise location of the container destination (or, for unloading, its current location). Choosing x o ,y o ,z o near that destination induces smaller errors in this derived position which occur due to mis-estimates of θ x ,θ y , and θ z .
The general equation of ship motion is given by:
x(t)=Φ(t,t.sub.O)x(t.sub.O)+w(t,t.sub.O) (1)
where
x(t)=(x.sub.O,y.sub.O,z.sub.O,θ.sub.X,θ.sub.Y,θ.sub.Z,x'.sub.O,y'.sub.O,z'.sub.O,θ'.sub.X,θ'.sub.Y,θ'.sub.Z).sub.T(2)
Φ(t,t O )=State Transition Matrix
w(t,t O )=Process noise.
As described hereinbefore, changes in the position-state vector occur over very long periods (several minutes, or even hours) as a result of wind, tide, and overall cargo weight, and over short periods (20 seconds to a minute) as a result of wave motion, cargo loading and ballast changes. Over the time intervals of interest, during which a container is being loaded and controls must be applied to change its destination (20-40 seconds), the long-term motions are imperceptible. The short-term motions, however, are too severe to be ignored, and too unpredictable to be extrapolated linearly for more than a few seconds. The solution is to employ a first-order model for predictions from one observation to the next (1/8 second), and to predict position several seconds ahead (for the purpose of control) by simply using the most recent filtered position.
An alternative to the first-order model is the Integrated Ornstein-Uhlenbeck (IOU) model, in which the first-derivative states are heavily damped, so they decay to zero in a few seconds. The defining equation for this model is: ##EQU1## where λ>0 is an arbitrary time constant. The same model could then be used for both the prediction/observation process and for extrapolating the position of the ship to a future time. At the present time, the additional complexity of this solution does not seem justified.
Another alternative is to attempt to model the apparent damped harmonic motion observed in the ship motion data. The defining equation for this model is:
x(t+Δt)=x(t)+x'(t)Δte.sup.-λΔt (a.sub.1 cos(wΔt)+a.sub.2 sin(wΔt)) (4)
where a 1 , a 2 and w are constant parameters which must be estimated by the filter. The problem with this model, of course, is that much of the power spectrum obtained from the raw data was not located at a single characteristic frequency, and thus a 1 , a 2 and w may be very hard to estimate with enough accuracy to give good predictions for x(t+Δt). For this reason, a harmonic motion model is not contemplated.
The noise w in equation (1) is modeled as white, zero-mean Gaussian, with covariance GQG T . A preliminary estimate for the variance of roll rate, based on data, observations and measurements indicate that the maximum rate of motion of the side of the ship is approximately one inch per second, and the minimum is zero, at least three seconds later. This implies an acceleration on the order of one-third inch/sec 2 , which corresponds to an angular acceleration of 3×10 -2 deg/sec 2 . Over the time between observations (1/8 second), dθ Y /dt has a maximum change of 4.13×10 -3 deg/sec. This data is fitted with a Gaussian distribution by taking the maximum change to be a 3-sigma value, to give var(dθ Y /dt)˜1.7×10 -7 (deg/sec) 2 . Of course, the model assumes white noise, whereas the data is highly time-correlated, so this estimate may need some modification in actual practice. Estimates for variances in velocity in the x-direction (perpendicular to the pier) and in the y-direction (along the pier) are estimated at about 2.0×10 -4 (inch/sec) 2 . It is known that the magnitude of changes in those states are much smaller than for roll, and for lateral/fore-and-aft motion. Consequently, the variances on all other derivatives are taken to be 1/100 that of the corresponding derivatives on data is available. Since there is no known correlation amongst the states, all off-diagonal elements of GQG T are zero. Finally, the changes in the position and orientation states are accounted for by their derivative states, and consequently the upper- and left-halves of GQG T are zero.
To obtain the estimated vector e, the system estimates x by a 12-state vector e in a three-step process. First an a priori estimate e O is derived from data supplied by the crane control processor. When the first container in a tier is loaded onto the ship, the estimated values of x O , y O ,z O , are deduced from the known location of that container on the ship, and the position of the container relative to the crane structure when it was loaded. For the theoretical model, it is assumed that the first container is always loaded at (x O ,y O ), and z O is at sea level. Values for θ X ,θ Y ,θ Z are taken from the first range observations, as described below. The time of validity of the initial estimate x O is also noted.
Each time the sensors produce new data, those sensor data are applied, using the observation models described hereinafter to produce a corrected estimate e i+1 .
The range finders supply a three-state vector r=(r 1 , r 2 , r 3 ) T consisting of the three simultaneous ranges to the hull. The observation model is given by:
r=h(x)+z (5)
where x is the state vector, h is a non-linear observation function, and z is white zero-mean Gaussian noise with a priori covariance matrix given by R=zz T . Note that this observation model is substantially different from a linear model in that absolute measurements are taken, rather than relative. This requires modification to a non-linear or extended Kalman filter (EKF), but is justified by the high accuracy observed in ultrasound range finders, and the consequent high accuracy that can be achieved in the state estimates.
The function h is defined as follows. First, the ship side is modeled in the region of interest as a plane, parallel to the fore-and-aft axis of the ship, at a distance h from the center. An equation for this plane is:
(x-p)n=h, (6)
where
p=(x P ,y P ,z P ) T =a point on the plane
x=(x O ,y O ,z O ) T =position portion of the state vector
n=a vector normal to the plane.
The normal vector n is simply the unit vector in the x-direction, rotated to align with the ship. Thus: ##EQU2##
The range finders measure distance from the y-z plane to the ship side; that is, each range finder determines x P , from a point in the y-z plane. Substituting (7) into (6) and solving for x P , ##EQU3##
The three range finders are placed at (O,O,O), (O,O,a) and (O,b,O) respectively, and are aimed parallel to the x-axis. The three corresponding ranges are:
r.sub.1 =(h+x.sub.O cosθ.sub.Z cosθ.sub.Y +y.sub.O cosθ.sub.Y sinθ.sub.Z +z.sub.O cosθ.sub.X sinθ.sub.Y -y.sub.O cosθ.sub.Z sinθ.sub.X sinθ.sub.Y
+x.sub.O sinθ.sub.Z sinθ.sub.X sinθ.sub.Y)/(cosθ.sub.Z cosθ.sub.Y +sinθ.sub.Z sinθ.sub.X sinθ.sub.Y) (9)
r.sub.2 =(h+x.sub.O cosθ.sub.Z cosθ.sub.Y +y.sub.O cosθ.sub.Y sinθ.sub.Z -a cosθ.sub.X sinθ.sub.Y
+Z.sub.O cosθ.sub.X sinθ.sub.Y -y.sub.O cosθ.sub.Z sinθ.sub.X sinθ.sub.Y
+x.sub.O sinθ.sub.Z sinθ.sub.X sinθ.sub.Y)/(cosθ.sub.Z cosθ.sub.Y +sinθ.sub.Z sinθ.sub.X sinθ.sub.Y) (10) ##EQU4##
The observation function h is used to derive the predicted measurement in the filter equations; however, for updating the covariance of the filter estimates the observation matrix H is required which is the 3×12 Jacobian dr/dx, of which the last six columns, corresponding to the derivative states of x, are all zero. The remaining 18 entries of H have been published and are not included herein in the interest of brevity.
The assumption that the ship side is planar is critical to this analysis. For most container ships, this assumption is valid, except possibly at the most extreme rows of containers, near the bow and stern of the ship. This is because the superstructures of most ships are at the ends, and the ships are designed to stow containers efficiently in their holds, so they have flat sides. However, some ships, including C10 ships, carry containers all the way forward and all the way aft, and have slightly rounded sides for greater seaworthiness. For these ships, the predicted position, based on the equation above, would be corrected by adjustments of the measurements at that position, based on detailed ship plans kept in the sensor system data base.
The second measurement vector consists of video observations of motions of the side of the ship, in the plane perpendicular to the line of sight:
v=(Δx,Δy), (12)
where Δx is the lateral motion of a point on the ship side, and Δy is the vertical motion, since the last observation.
Letting (x,y,z) be a point within the observation field of the video camera, then: ##EQU5##
Note that the video observation type differs from the range finder type in two important ways. First, no absolute information is obtained, so these data cannot be used to initialize the position vector, and second, because only relative motion is seen, the observation is very well approximated by a linear model. The implication of this second feature is that the usual Kalman filter update can be used. The 2×12 observation matrix H is the Jacobian dv/dx associated with the observation v. The non-zero states of H have also been published and are not included here in the interest of brevity.
In addition to calculating the filter variables, the sensor system must test each observation after the first for credibility. This is accomplished by comparing the actual observation with the observation which was predicted from the previous updated state vector. Variations larger than a given value will result in an alarm being sent to the crane operator, indicating that manual loading should be used until the sensor data falls within these reasonable limits.
For the motion model, the predicted position p at the time of the i th observation is calculated by the formula:
P.sub.i =Φe
and the covariance in p, denoted P i , is predicted by
P.sub.i =ΦP.sub.i Φ.sup.T +GQG.sup.T,
where
GQG T =covariance matrix of the process noise.
Φ=linear extrapolation matrix.
Finally, the updated estimate of the position is given by:
e.sub.i+1 =Φe.sub.i +K(z-hΦe.sub.i) (14)
where K is a 12×3 gain matrix defined by:
K=P.sub.i H.sup.T [HP.sub.i H.sup.T +R].sup.-1, (15)
and the covariance of the estimate is given by:
P.sub.i+1 =(I-KH)P.sub.i, (16)
where I is the 12×12 identity matrix.
In the actual sensor system, these estimated values will be sent to the crane control processor 37 (FIG. 5), which converts them into an estimated position for the next container and an estimate of error in that prediction. This allows the next container to be quickly and automatically moved to that precise spot, with the state vector being continually updated to adjust for any additional motion of the ship.
As discussed hereinbefore, ultrasonic range finders 27, 28 and 29, as well as video camera 30, must be provided with weather-proof and vibration-free support housings 43.
Operating power for all sensors will be provided by a DC power supply (not shown). The Type J thermocouple 51 can sense the ambient temperature inside the enclosure and provide input to a single setpoint controller. This controls current flow to the heater-resistor 50 mounted inside the enclosure. The heater 50 is activated when necessary to ensure proper operation of the sensors.
In the specific embodiment described herein the ultrasonic range finders 27,28,29 were one way type electronic transducers as employed in Polaroid ultrasonic ranging systems.
The video lens system employed must be capable of focusing on an area approximately three feet square at the minimum range to the ship from the crane and automatic focusing is required. A 510 (H)×492 (V) pixel charge coupled device (CCD), Model No. WV-CDSO was employed for the specific embodiment of the present invention described herein. This device was manufactured by Panasonic and OEMed by Cognex as a component of their Cognex 2000 series Frame Grabber and processor.
Although the invention has been described relative to specific embodiments thereof, it is not so limited and there are numerous modifications and variations thereof that will be readily apparent to those skilled in the art in the light of the above teachings.
For example, although the invention has been described relative to container ship loading/unloading, it is equally applicable to measuring six degrees of freedom movement of any large object.
It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein.
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A system is disclosed for accurately measuring the position of a moored container ship relative to a fixed pier after loading or unloading each container on the ship and including a processor mechanism employed to combine the measured relative position with previously acquired data indicating the ship position prior to the loading or unloading of the previous container, and utilizing the combined data to facilitate automatic control of placing or removing a subsequent container on the ship by a crane structure. The system is applicable for measuring six degrees of freedom of movement of any large object.
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This application is based on Application No. 2001-229685, filed in Japan on Jul. 30, 2001, the contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a steering control apparatus, and more specifically, it relates to an electric power steering control apparatus which controls an assisting force applied by a motor to a steering system of a vehicle based on at least the steering torque of a steering wheel and the speed of the vehicle when the steering wheel is steered to turn by a driver.
2. Description of the Related Art
There have been developed electric power steering apparatuses in which the speed of a vehicle and the steering torque applied to a steering column or shaft are detected, and a driving current determined according to the vehicle speed and the steering torque thus detected is supplied to a motor which generates an assisting force given to the steering shaft, so that the motor is thereby driven to rotate, thus assisting the force required to steer the vehicle by means of the rotating force of the motor to provide the driver with a pleasant steering sensation or feeling.
In the past, a DC motor with a brush has been used as a motor which gives an assisting force to a steering shaft of a vehicle, but it is impossible to perform field control with the DC motor and hence conventional electric power steering control apparatuses are not equipped with any means for generating a target current value used to carry out field control.
Moreover, there can be considered a steering control apparatus which employs a brushless motor in place of such a DC motor, as a motor for applying an assisting force to the steering shaft. In this case, owing to the absence of any brush within an electric motor, there will take place almost no abnormality or fault in the motor itself, and it also becomes possible to effect field control, which could not been carried out in the past as referred to above.
A brushless motor control apparatus performs a variety of calculations such as the calculation of a dq-axis target current based on an instruction torque, the detection of currents for respective phases (e.g., u phase and v phase) of a motor, the dq conversion of currents, the calculation of current deviations, the calculation of instruction voltage values, dq inversions, and the output of PWM control patterns. The detected respective phase currents are subjected to dq conversion in such a manner that they are controlled in a feedback manner to make their d-axis component and q-axis component equal to a d-axis target current and a q-axis target current, respectively. The d-axis component of each current means a wattless or reactive current, whereas the q-axis component is proportional to the torque of the motor when the motor is a synchronous motor and when the magnitude of the excitation magnetic field is constant. Therefore, the current feedback control for the synchronous motor is generally carried out in such a manner that the d-axis component of the detected current becomes zero and the q-axis component thereof becomes equal to a target value of the output torque.
In cases where a steering control apparatus is installed on a vehicle with a large weight, a large motor output torque is required, and there will be a problem that in cases where the motor characteristic is of the high-torque and low-rotation type, the output torque of the motor rapidly decreases upon rapid steering. As a result, in the case of an electric power steering control apparatus, there arises a problem that the steering operation rapidly becomes heavy upon rapid steering, whereas in the case of a steer-by-wire steering system, there is a problem in that the actual steering angle of the steered wheels does not follow the steering angle of the steering wheel upon rapid steering.
However, where the motor characteristic is of the low-torque and high-speed rotation type, it is necessary to increase the motor current in order to enlarge the motor output torque, and hence a large-sized motor of high power consumption is required. With a steering apparatus which is to be installed in a limited space, however, it becomes important to suppress the power consumption of a motor used therein and reduce the size thereof.
SUMMARY OF THE INVENTION
The present invention is intended to obviate the various problems as referred to above, and has for its object to provide a steering control apparatus which is capable of alleviating a decrease in the output torque of a motor during high-speed steering without increasing the size thereof.
Bearing the above object in mind, according to the present invention, there is provided a steering control apparatus including a motor, a motor current instruction value generation section for generating a current instruction value for the motor, and a motor current detection section for detecting a current flowing through the motor, the motor being driven to operate based on at least the current flowing through the motor and the current instruction value, wherein the motor current instruction value generation section includes a correction section for correcting a current instruction value which controls a magnetic field of a field magnet of the motor, the correction section being operable to correct the current instruction value for controlling the magnetic field of the motor field magnet when a steering speed is high,
In a preferred form of the present invention, the steering control apparatus further comprises a motor control section for performing torque control on the motor in accordance with a torque instruction through vector control which is represented by a two-phase rotating magnetic flux coordinate system having a direction of a field current oriented in a d-axis direction and a direction perpendicular to the d-axis oriented in a q-axis direction, wherein the correction section corrects a d-axis current instruction value in such a manner that a d-axis current is controlled to such a predetermined value as to weaken the magnetic field of the motor field magnet when a deviation between the q-axis current instruction value and a q-axis current detection value becomes not less than a predetermined value.
In another preferred form of the present invention, the correction section increases a negative d-axis current instruction value for weakening the magnetic field of the motor field magnet when the q-axis current deviation is not less than a first predetermined value, and decreases the negative d-axis current instruction value for weakening the magnetic field of the motor field magnet when the q-axis current deviation is not greater than a second predetermined value.
In a further preferred form of the present invention, the d-axis current instruction value is limited within a preset range.
In a still further preferred form of the present invention, the steering control apparatus further comprises a stator phase current instruction value generation section for generating stator respective phase current instruction values from the q-axis current instruction value, wherein the current instruction value for controlling the magnetic field of the motor field magnet is corrected based on a deviation between at least one of the stator phase current instruction values and an actual corresponding stator phase current value in place of the q-axis current deviation.
In a yet further preferred form of the present invention, the steering control apparatus further comprises a reference steering torque generation section for generating a reference steering torque which is used to determine whether the magnetic field of the motor field magnet is to be weakened, wherein when the steering torque becomes not less than the reference steering torque, the correction section corrects the current instruction value to such a prescribed value as to weaken the magnetic field of the motor field magnet.
In a further preferred form of the present invention, the reference steering torque generation section generates the reference steering torque as a function of at least a vehicle speed.
In a further preferred form of the present invention, the steering control apparatus further comprises a steering speed detection section for detecting a steering speed of a steering wheel, wherein the correction of the current instruction value for controlling the magnetic field of the motor field magnet is effected such that when the steering speed of the steering wheel becomes not less than a predetermined value, the current instruction value is corrected to such a prescribed value as to weaken the magnetic field of the motor field magnet.
In a further preferred form of the present invention, the steering control apparatus further comprises: a motor control section for performing torque control on the motor in accordance with a torque instruction through vector control which is represented by a two-phase rotating magnetic flux coordinate system having a direction of a field current oriented in a d-axis direction and a direction perpendicular to the d-axis direction oriented in a q-axis direction; a speed detection section for detecting a rotational speed of the motor; and a voltage limitation value generation section for generating a voltage limitation value to a voltage applied to the motor; wherein the correction section determines a d-axis current value for setting a working point on a voltage limitation circle through calculations based on at least the rotational speed of the motor, a q-axis current instruction value, a stator winding resistance, a stator winding reactance and a motor counter electromotive voltage constant, and effects correction in such a manner that when the d-axis current value determined through calculations is a current value which weakens the magnetic field of the motor field magnet more than a d-axis current instruction value does, the d-axis current value determined through calculations becomes equal to the d-axis current instruction value.
In a further preferred form of the present invention, the steering control apparatus further comprises a power supply voltage detection section for detecting a power supply voltage, wherein the voltage limitation value generation section generates, as a voltage limitation value, a value obtained by multiplying the power supply voltage by a predetermined coefficient.
In a further preferred form of the present invention, the motor comprises a field winding type motor, and the apparatus further comprises a motor control section for performing torque control on the motor in accordance with a torque instruction in such a manner that a field winding current instruction value is corrected when a deviation between an armature current instruction value and an armature current detection value becomes not less than a predetermined value.
In a further preferred form of the present invention, the field winding current instruction value is corrected in such a manner that it is decreased when the armature current deviation is not less than a first predetermined value, and it is increased when the armature current deviation is not greater than a second predetermined value.
In a further preferred form of the present invention, the field winding current instruction value is limited to a preset minimum value.
In a further preferred form of the present invention, the correction section corrects the current instruction value with a correction value which is determined through calculations.
In a further preferred form of the present invention, the correction section corrects the current instruction value with a correction value which is obtained by referring to a table prepared in advance.
In a further preferred form of the present invention, the d-axis current instruction value is limited to a value which is obtained by vector subtracting a q-axis current value from a preset maximum current vector value.
In a further preferred form of the present invention, an integrated value of the deviation is used in place of the deviation.
In a further preferred form of the present invention, the correction section corrects the current instruction value for controlling the magnetic field of the motor field magnet only when a vehicle speed is not less than a predetermined value.
In a further preferred form of the present invention, the correction section corrects the current instruction value for controlling the magnetic field of the motor field magnet only when a steering torque is not less than a predetermined value.
The above and other objects, features and advantages of the present invention will become more readily apparent to those skilled in the art from the following detailed description of preferred embodiments of the present invention taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a constructional view illustrating a first embodiment of the present invention.
FIG. 2 is a block diagram illustrating functions of the first embodiment of the present invention.
FIG. 3 is a flow chart illustrating d-axis target current correction processing according to the first embodiment of the present invention.
FIG. 4 is a view illustrating examples of waveforms before and after modulation in the first embodiment of the present invention.
FIG. 5 is a block diagram illustrating a second embodiment of the present invention.
FIG. 6 is a flow chart illustrating d-axis target current correction processing in the second embodiment of the present invention.
FIG. 7 is a block diagram illustrating functions of a third embodiment of the present invention.
FIG. 8 is a flow chart illustrating d-axis target current correction processing in the third embodiment of the present invention.
FIG. 9 is a block diagram illustrating functions of a fourth embodiment of the present invention.
FIG. 10 is a flow chart illustrating d-axis target current correction processing in the fourth embodiment of the present invention.
FIG. 11 is a block diagram illustrating functions of a fifth embodiment of the present invention.
FIG. 12 is a flow chart illustrating d-axis target current correction processing in the fifth embodiment of the present invention.
FIG. 13 is a block diagram illustrating functions of a sixth embodiment of the present invention.
FIG. 14 is a flow chart illustrating d-axis target current correction processing in the sixth embodiment of the present invention.
FIG. 15 is a block diagram illustrating functions of a seventh embodiment of the present invention.
FIGS. 16A through 16D are dq-axis vector diagrams for explaining magnetic flux weakening control according to the seventh embodiment of the present invention.
FIG. 17 is a flow chart illustrating d-axis target current correction processing in the seventh embodiment of the present invention.
FIG. 18 is a block diagram illustrating an eighth embodiment of the present invention.
FIG. 19 is a flow chart illustrating field current instruction value correction processing in the eighth embodiment of the present invention.
FIG. 20 is a steering speed vs. steering torque characteristic view illustrating effects of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Now, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings by taking, as an example, the case where the present invention is applied to an electric power steering control apparatus.
Embodiment 1
In a first embodiment of the present invention, a d-axis target current is corrected as a function of a deviation in a q-axis current thereby to decrease the magnetic field of a field magnet of a motor upon high-speed steering in which the deviation in the q-axis current increases due to voltage saturation, thus alleviate an increase in steering torque during such high-speed steering.
FIG. 1 is a constructional view illustrating an electric power steering control apparatus according to this first embodiment of the present invention.
In this figure, a motor 5 , which generates steering assisting torque, is connected through a reduction gear 4 with one end of a steering column or shaft 2 , the other end of which is connected with a steering wheel 1 . Also connected with the steering shaft 2 is a torque sensor 3 for detecting the steering torque of the steering wheel 1 to generate a corresponding torque detection value.
A controller 100 serves to determine a steering assisting torque based on the torque detection value of the torque sensor 3 and a vehicle speed detection value detected by a vehicle speed sensor 6 , and assist the steering operation of the steering wheel 1 by driving the motor 5 to generate the steering assisting torque thus determined. A battery 7 is connected with an ignition key 8 and the controller 100 .
FIG. 2 functionally illustrates an example of the electric power steering control apparatus according to the first embodiment of the present invention in which a PM brushless motor is used as a steering assisting motor.
In FIG. 2, a reference numeral 100 designates a microcomputer which performs steering assisting control with its software configuration being illustrated in a functional block diagram.
In FIG. 2, the microcomputer 100 includes a q-axis target current calculation section 100 a , a d-axis target current correction section 100 b acting as a correcting section, a position calculation section 100 c , a uv to dq transformation section 100 d , a current control section 100 e , a dq to uvw transformation section 100 f acting as a stator phase current instruction value generation section, a voltage utilization efficiency improvement section 100 o , a dead band (Td) correction section 100 p , an angular velocity calculation section 100 q acting as a speed detection section, a decoupled control section 100 r , and a current detection offset correction section 100 s . Here, note that the q-axis target current calculation section 100 a and the d-axis target current correction section 100 b together constitute a motor current instruction value generation section.
The q-axis target current calculation section 100 a performs predetermined calculations based on the torque detection signal of the torque sensor 3 , which detects the steering torque of the steering wheel 1 , and the vehicle speed detection signal of the vehicle speed sensor 6 , which detects the vehicle speed, determines a q-axis target current value (Iq*) for driving the motor 5 in the form of a PM brushless motor, and supplies the q-axis target current value thus determined to the current control section 100 e.
The position calculation section 100 c determines an electrical angle θ through calculations based on the positional detection signal of a position sensor 103 , and supplies the electrical angle θ thus determined to the angular velocity calculation section 100 q , the uv to dq transformation section 100 d and the dq to uvw transformation section 100 f.
The angular velocity calculation section 100 q determines a motor rotational angular velocity ω through calculations based on the electrical angle θ, and supplies it to the decoupled control section 100 r.
The current detection offset correction section 100 s calculates respective phase detection currents (Iu, Iv) by subtracting the amounts of respective phase offsets from phase current values detected by current sensors 102 a , 102 b , respectively, and supplies them to the Td correction section 100 p and the uv to dq transformation section 100 d.
The uv to dq transformation section 100 d performs dq conversion based on the detected phase current values (Iu, Iv) and the electrical angle θ, and supplies thus converted dq-axis currents (Id, Iq) to the decoupled control section 100 r and the current control section 100 e.
FIG. 3 is a flow chart for explaining the processing performed by the d-axis target current correction section 100 b.
In step S 1 , it is determined whether the vehicle speed detected by the vehicle speed sensor 6 is not less than a predetermined value, and when the detected vehicle speed is less than the predetermined value, the d-axis target current (Id*) is adopted as a corrected d-axis target current (Id**) in step S 5 , whereas when the detected vehicle speed is not less than the predetermined value, the control process advances to the processing of step S 2 . Then, in step S 2 , it is determined whether the steering torque detected by the torque sensor 3 is not less than a predetermined value, and when the detected steering torque is less than the predetermined value, the d-axis target current (Id*) is adopted as the corrected d-axis target current (Id**) in step S 5 , whereas when the detected steering torque is not less than the predetermined value, the control process advances to the processing of step 3 . In step S 3 , it is determined whether a q-axis current deviation (ΔIq) is not less than a predetermined value, and when the q-axis current deviation (ΔIq) is less than the predetermined value, the d-axis target current (Id*) is adopted as the corrected d-axis target current (Id**) in step S 5 , whereas when the q-axis current deviation (ΔIq) is not less than the predetermined value, the control process advances to the processing of step 4 . In step 4 , the d-axis target current is corrected by subtracting a corrected current value (f(ΔIq)), which is obtained as a function of the q-axis current deviation (ΔIq), from the d-axis target current (Id*), and the thus corrected d-axis target current (Id**) is supplied to the current control section 100 e.
The current control section 100 e performs proportional and integral (PI) control based on deviations between the dq-axis target currents (Id**, Iq*) and the corresponding detected dq-axis currents (Id, Iq), and generates dq-axis target application voltages (Vd*, Vq*).
The control section 100 r calculates non-interfering voltages based on the dq-axis detection currents (Id, Iq) and the motor angular velocity ω, and corrects the dq-axis target application voltages (Vd*, Vq*) to generate corrected dq-axis target application voltages (Vd**, Vq**), which is supplied to the dq to uvw transformation section 100 f.
The dq to uvw transformation section 100 f performs dq inversion based on the corrected dq-axis target application voltages (Vd**, Vq**) and the electrical angle θ to generate three-phase target application voltages (Vu*′, Vv*′, Vw*′), which are supplied to the voltage utilization efficiency improvement section 100 o.
To improve the voltage efficiency, the voltage utilization efficiency improvement section 100 o modulates the three-phase target application voltages (Vu*′, Vv*′, Vw*′) into a spatial voltage vector, and supplies the thus modulated three-phase target application voltages (Vu*″, Vv*″, VW*″) to the Td correction section 100 p . Examples of waveforms before and after such modulation are illustrated in FIG. 4 . In FIG. 4, the axis of ordinate represents the values of the three-phase target application voltages, and the axis of abscissa represents the rotational position of the motor.
The Td correction section 100 p performs dead band compensation for the modulated three-phase target application voltages (Vu*″, Vv*″, Vw*″) based on the detected current values (Iu, Iv, Iw), and supplies the thus compensated three-phase target application voltages (Vu*, Vv*, Vw*) to a driving section 101 .
With the electric power steering control apparatus as constructed above, owing to the provision of the d-axis target current correction section 100 b , the magnetic field of the motor field magnet is weakened during high-speed steering in which the q-axis current deviation is increased due to voltage saturation so that a decrease in the output torque of the steering assisting motor upon rapid steering can be alleviated, thus making it possible to reduce the increasing steering torque during such rapid steering.
Although in the first embodiment, the electric power steering control apparatus has been taken as an example, the present invention may instead be applied to a steer-by-wire steering control apparatus.
In the case of such a steer-by-wire steering control apparatus, owing to the provision of the d-axis target current correction section 100 b , the magnetic field of the motor field magnet can be weakened upon high-speed steering in which the q-axis current deviation is increased due to voltage saturation, whereby a decrease in the motor output torque upon rapid steering can be alleviated, thus improving the followability of the actual steering angle with respect to the operator's induced steering angle during rapid steering.
Embodiment 2
In a second embodiment of the present invention, the d-axis target current is corrected with a current value which is obtained by referring to a table, which has been prepared in advance using the q-axis current deviation as a parameter, thereby to decrease the magnetic field of the motor field magnet upon high-speed steering in which the q-axis current deviation increases due to voltage saturation, thus alleviating an increase in steering torque during such high-speed steering.
FIG. 5 functionally illustrates an example of an electric power steering control apparatus according to the second embodiment of the present invention in which an induction motor is used as a steering assisting motor. In FIG. 5, description will be made with the same or corresponding parts as those in FIG. 2 being identified by the same symbols.
In FIG. 5, there is illustrated a functional block diagram of a microcomputer, generally designated at 100 , which performs steering assisting control by executing software incorporated therein. The microcomputer 100 of this second embodiment includes a dq-axis target current calculation section 100 a , a d-axis target current correction section 100 b , a slip angle frequency calculation section 100 l , a power supply angular frequency calculation section 100 m which calculates a power supply angular frequency from a slip angle frequency ωs and a motor rotational speed ωr of an induction motor 5 a detected by a speed sensor 104 , an integrator 100 n which calculates an angle θ from the power supply angular frequency, a uv to dq transformation section 100 d , a current control section 100 e , and a dq to uvw transformation section 100 f.
FIG. 6 is a flow chart for explaining the processing performed by the d-axis target current correction section 100 b in the electric power steering control apparatus according to the second embodiment of the present invention.
In step S 1 , it is determined whether the vehicle speed detected by the vehicle speed sensor 6 is not less than a predetermined value, and when the detected vehicle speed is less than the predetermined value, the d-axis target current (Id*) is adopted as a corrected d-axis target current (Id**) in step S 5 , whereas when the detected vehicle speed is not less than the predetermined value, the control process advances to the processing of step S 2 . Then, in step S 2 , it is determined whether the steering torque detected by the torque sensor 3 is not less than a predetermined value, and when the detected steering torque is less than the predetermined value, the d-axis target current (Id*) is adopted as the corrected d-axis target current (Id**) in step S 5 , whereas when the detected steering torque is not less than the predetermined value, the control process advances to the processing of step S 3 .
In step S 3 , it is determined whether the q-axis current deviation (ΔIq) is not less than a predetermined value, and when the q-axis current deviation (ΔIq) is less than the predetermined value, the d-axis target current (Id*) is adopted as the corrected d-axis target current (Id**) in step S 5 , whereas when the q-axis current deviation (ΔIq) is not less than the predetermined value, the control process advances to the processing of step S 6 . In step S 6 , a corrected current value (Ida) is determined by referring to a table, which has been prepared in advance using the q-axis current deviation (ΔIq) as a parameter. In step S 4 , the d-axis target current is corrected by subtracting the corrected current value (Ida) from the d-axis target current (Id*), and the thus corrected d-axis target current (Id**) is supplied to the current control section 100 e.
Embodiment 3
In a third embodiment of the present invention, the d-axis target current value is corrected in such a manner that it is decreased when an integrated value of the q-axis current deviation is not less than a first predetermined value 1, and increased when the integrated q-axis current deviation is not greater than a second predetermined value 2, whereby the magnetic field of the motor field magnet is weakened upon high-speed steering in which the q-axis current deviation increases due to voltage saturation, thus alleviating an increase in the steering torque during such high-speed steering.
FIG. 7 functionally illustrates an example of an electric power steering control apparatus according to the third embodiment of the present invention in which a PM brushless motor is used as a steering assisting motor. In FIG. 7, the same or corresponding parts as those in FIG. 2 are identified by the same symbols while omitting a detailed description thereof.
FIG. 8 is a flow chart for explaining the processing performed by a dq-axis target current correction section 100 g.
In step S 10 , the q-axis current deviation ΔIq is integrated, and in step S 11 , it is determined whether the integrated value of ΔIq is not less than the first predetermined value 1. When the integrated value of ΔIq is not less than the first predetermined value 1, a d-axis current correction amount Ida is increased in step S 12 , and the correction value is limited to a preset maximum correction value Ida_max in step S 13 . On the other hand, when the integrated value of ΔIq is less than the first predetermined value 1, it is further determined whether the integrated value of ΔIq is not greater than a second predetermined value 2 in step S 14 . When the integrated value of ΔIq is not greater than the second predetermined value 2, the d-axis current correction amount Ida is decreased in step S 15 , and the correction value is limited to a preset minimum correction value Ida_min in step S 16 . Then in step S 17 , a corrected d-axis target current value (Id**) is calculated by subtracting the d-axis current correction value (Ida) from the d-axis target current (Id*).
Subsequently, in step S 20 , a maximum d-axis target current (Id_max) is calculated by subtracting the q-axis target current value (Iq*) from a preset maximum current vector value (Ia). In step S 21 , it is determined whether the corrected d-axis target current value (Id**) is greater than the maximum d-axis target current (Id_max). When the corrected d-axis target current value (Id**) is greater than the maximum d-axis target current (Id_max), the maximum d-axis target current (Id_max) is adopted as the corrected d-axis target current value (Id**) in step S 22 .
Embodiment 4
In a fourth embodiment of the present invention, when the steering torque exceeds a prescribed torque value, the d-axis target current is corrected in such a manner as to decrease the magnetic field of the motor field magnet, whereby the magnetic field is weakened upon high-speed steering in which the steering assisting torque is reduced due to voltage saturation, thus alleviating an increase in the steering torque during such high-speed steering.
FIG. 9 functionally illustrates an example of an electric power steering control apparatus according to the fourth embodiment of the present invention in which a PM brushless motor is used as a steering assisting motor. In FIG. 9, the same or corresponding parts as those in FIG. 2 are identified by the same symbols while omitting a detailed description thereof.
In FIG. 9, a motor angular velocity calculation section 100 i determines a motor rotational angular velocity ω through calculations based on the electrical angle θ from the position calculation section 100 c , and supplies it to the d-axis target current correction section 100 b.
FIG. 10 is a flow chart for explaining the processing performed by the d-axis target current correction section 100 b in the electric power steering control apparatus according to the fourth embodiment of the present invention.
In step S 30 , it is determined whether the motor angular velocity ω is not less than a predetermined value, and when the motor angular velocity ω is less than the predetermined value, the d-axis target current (Id*) is adopted as the corrected d-axis target current (Id**) in step S 36 , whereas when the motor angular velocity ω is not less than the predetermined value, the control process advances to reference torque Ts_ref calculation processing in step 31 . In the reference torque Ts_ref calculation processing in step S 31 (i.e., a reference steering torque generation section), a reference torque Ts_ref is determined by referring to a table, which has been prepared in advance as a function of the vehicle speed detected by the vehicle speed sensor 6 or by the use of the detected vehicle speed as a parameter, alternatively it is determined as a preset constant value instead of referring to such a table. In step S 32 , a comparison is made between the torque sensor signal (Ts) and the reference torque (Ts_ref), and when the torque sensor signal (Ts) is not greater than the reference torque (Ts_ref), the d-axis target current (Id*) is adopted as the corrected d-axis target current (Id**) in step S 36 , whereas when the torque sensor signal (Ts) is greater than the reference torque (Ts_ref), the control process advances to the processing in step S 33 .
In step S 33 , a difference ΔTs between the torque sensor signal (Ts) and the reference torque (Ts_ref) is calculated by subtracting the reference torque (Ts_ref) from the torque sensor signal (Ts). Then in the correction current Ida calculation processing in step S 34 , a correction current Ida is calculated by referring to a table, which has been prepared in advance as a function of ΔTs or using ΔTs as a parameter. In step S 35 , a corrected d-axis target current (Id**) is calculated by subtracting the correction current (Ida) from the d-axis target current (Id*), and the thus corrected d-axis target current (Id**) is supplied to the current control section 100 e.
Embodiment 5
In a fifth embodiment of the present invention, when the motor rotational speed exceeds a predetermined value, the current instruction value for controlling the magnetic field of the motor field magnet is corrected to such a prescribed value as to decrease the magnetic field, whereby the magnetic field is weakened upon high-speed steering, thus alleviating an increase in the steering torque during such high-speed steering.
FIG. 11 functionally illustrates an example of an electric power steering control apparatus according to the fifth embodiment of the present invention in which a PM brushless motor is used as a steering assisting motor. In FIG. 11, the same or corresponding parts as those in FIGS. 2 and 9 are identified by the same symbols while omitting a detailed description thereof.
FIG. 12 is a flow chart for explaining the processing performed by the d-axis target current correction section 100 b.
In step S 40 , it is determined whether the motor angular velocity ω is not less than a predetermined value, and when the motor angular velocity ω is less than the predetermined value, the d-axis target current (Id*) is adopted as the corrected d-axis target current (Id**) in step S 43 , whereas when the motor angular velocity ω is not less than the predetermined value, the control process advances to correction current Ida calculation processing in step 41 . In the correction current Ida calculation processing in step S 41 , a correction current Ida is calculated by referring to a table, which has been prepared in advance as a function of the motor angular velocity ω or using the motor angular velocity ω as a parameter. In step S 42 , a corrected d-axis target current (Id**) is calculated by subtracting the correction current (Ida) from the d-axis target current (Id*), and the thus corrected d-axis target current (Id**) is supplied to the current control section 100 e.
Embodiment 6
In a sixth embodiment of the present invention, when the steering speed exceeds a predetermined value, the current instruction value for controlling the magnetic field of the motor field magnet is corrected to such a prescribed value as to decrease the magnetic field, whereby the magnetic field is weakened upon high-speed steering, thus alleviating an increase in the steering torque during such high-speed steering.
FIG. 13 functionally illustrates an example of an electric power steering control apparatus according to the sixth embodiment of the present invention in which a field winding type motor is used as a steering assisting motor. In FIG. 13, the same or corresponding parts as those in FIG. 2 are identified by the same symbols while omitting a detailed description thereof.
In FIG. 13, the electric power steering control apparatus of this sixth embodiment includes a steering angle sensor 9 , a steering angular velocity calculation section 100 j acting as a steering speed detection section for determining a steering angular velocity ω′ based on the output of the steering angle sensor 9 , and a target current calculation section 100 t for determining a target armature current value (Ia*) and a target field winding current value (If*) to drive a field winding type motor 5 b based on the torque detection signal of the torque sensor 3 , which detects the steering torque, and the vehicle speed detection signal of the vehicle speed sensor 6 , which detects the vehicle speed. The target current calculation section 100 t supplies the thus determined target armature current value (Ia*) to the current control section 100 c , and the thus determined target field winding current value (If*) to a target field winding current correction section 100 h to be described later.
FIG. 14 is a flow chart for explaining the processing performed by the target field winding current correction section 100 h.
In step S 50 , it is determined whether the steering angular velocity ω′ is not less than a predetermined value, and when the steering angular velocity ω′ is less than the predetermined value, the target field winding current (If*) is adopted as the corrected target field winding current (If**) in step S 53 , whereas when the steering angular velocity ω′ is not less than the predetermined value, the control process advances to correction current Ifa calculation processing in step 51 . In the correction current Ifa calculation processing in step S 51 , a correction current Ifa is calculated by referring to a table, which has been prepared in advance as a function of the steering angular velocity ω′ or using the steering angular velocity ω′ as a parameter. In step S 52 , the corrected target field winding current (If**) is determined by subtracting the correction current (Ifa) from the target field winding current (If*), and the corrected target field winding current (If**) thus determined is supplied to the current control section 100 e.
Embodiment 7
In a seventh embodiment of the present invention, a d-axis current value (Ida) for setting a working point on a voltage limiting circle is determined through calculations based on a motor rotational speed detection value, a q-axis current instruction value, a stator winding resistance, a stator winding reactance and a motor counter electromotive voltage constant, and when the d-axis current value (Ida) thus calculated is such a current value as to weaken the magnetic field of the motor field magnet more than the d-axis current instruction value (Id*) does, the d-axis current instruction value is corrected in such a manner that the d-axis current value (Ida) calculated above becomes equal to the d-axis current instruction value, thereby weakening the magnetic field upon high-speed steering to alleviate an increase in the steering torque during such high-speed steering.
FIG. 15 functionally illustrates an example of an electric power steering control apparatus according to the seventh embodiment of the present invention in which a PM brushless motor is used as a steering assisting motor. In FIG. 15, the same or corresponding parts as those in FIG. 2 are identified by the same symbols while omitting a detailed description thereof.
The electric power steering control apparatus according to this seventh embodiment of the present invention substantially includes, in addition to the components of the aforementioned first embodiment, a power supply voltage sensor 10 acting as a power supply voltage detection section, a voltage limitation value generation section 100 k , and a motor angular velocity calculation section 100 i . The voltage limitation value generation section 100 k generates a voltage limitation value (V_lim) by multiplying the voltage detected by the power supply voltage sensor 10 by a predetermined coefficient, and supplies it to the d-axis target current correction section 100 b.
Here, a brief description of the magnetic field weakening control will be made using the following expression (1) and FIG. 16 .
A fundamental equation (under-mentioned expression (1)) for the PM brushless motor 5 is well-known as shown below.
V 2 =(φω+ Ri q −ωL d i d ) 2 +( Ri d +ωL q i q ) 2 (1)
where V represents a terminal voltage supplied to the motor; ω represents the angular velocity of the motor; R represents a stator winding resistance per phase; φ represents an unloaded induced voltage at a unit speed; L d and L q represent phase inductances for the d-axis and the q-axis, respectively; Id represents a d-axis current; and Iq represents a q-axis current.
FIGS. 16A through 16D are vector diagrams illustrating d-q rotating coordinate axes.
As the rotational speed ω of the PM brushless motor 5 increases, the voltage induced therein grows. When the voltage value V, which is a vector sum of the induced voltage ωφ, Ri q and ωL q i q , reaches the voltage limitation circle as illustrated in FIG. 16A, it becomes impossible for the PM brushless motor 5 to increase its rotational speed to a value equal to or higher than the rotational speed ω which is acquired by the motor 5 when the voltage value V has reached the voltage limitation circle.
However, with the electric power steering control apparatus, the rotational speed ω of the PM brushless motor 5 follows the steering speed of the steering wheel, so that the PM brushless motor 5 is forced to rotate at a speed higher than its own rotational speed performance at the time of high-speed steering of the steering wheel.
At this time, Ri q decreases due to an increase in the induced voltage ωφ under the restraint of the voltage value V, as illustrated in FIG. 16 B. As a result, the output torque of the PM brushless motor 5 is decreased, whereby the steering assisting torque is reduced, thus increasing the steering torque.
Here, by supplying the d-axis current for weakening the magnetic field of the motor field magnet, there is developed a voltage margin due to Rid and ωL d i d , as illustrated in FIG. 16 C.
Consequently, it becomes possible to cause the same amount of q-axis current as in FIG. 16A to flow at the same rotational speed as in FIG. 16B, as illustrated in FIG. 16 D.
As described above, a decrease in the output torque of the motor at high-speed rotation thereof can be alleviated by performing magnetic field weakening control, so that an increase in the steering torque during high-speed steering can be reduced.
FIG. 17 is a flow chart for explaining the processing performed by the d-axis target current correction section 100 b.
In step S 60 , it is determined whether the vehicle speed is not less than a predetermined value, and when the vehicle speed is less than the predetermined value, the d-axis target current (Id*) is adopted as the corrected d-axis target current (Id**) in step S 66 , whereas when the vehicle speed is not less than the predetermined value, the control process advances to Ida calculation processing in step S 61 . In the Ida calculation processing in step S 61 , a d-axis current instruction value (Ida) for setting a working point on the voltage limitation circle is calculated according to a predetermined calculation formula based on the detected motor rotational speed ω, the voltage limitation value (V_lim), the q-axis current instruction value, the stator winding resistance given in advance, the stator reactance given in advance, and the motor counter electromotive voltage constant given in advance. In step S 62 , a maximum d-axis target current (Id_max) is calculated by subtracting a q-axis detection current value (Iq) from a preset maximum current vector value (Ia).
In step S 63 , it is determined whether the d-axis current instruction value (Ida) calculated in step S 61 for setting a working point on the voltage limitation circle is greater than the maximum d-axis target current (Id_max). When the d-axis current instruction value (Ida) is greater than the maximum d-axis target current (Id_max), the maximum d-axis target current (Id_max) is adopted as the corrected d-axis target current value (Id**) in step S 64 . On the other hand, when the d-axis current instruction value (Ida) is less than the maximum d-axis target current (Id_max), the d-axis current instruction value (Ida) is adopted as the corrected d-axis target current value (Id**). The corrected d-axis target current (Id**) calculated according to the above-mentioned steps is supplied to the current control section 100 e.
Embodiment 8
In an eighth embodiment of the present invention, the field winding current instruction value is corrected as a function of an armature current deviation (ΔIa), whereby the magnetic field of the motor field magnet is weakened upon high-speed steering in which the armature current deviation is increased due to voltage saturation, thus alleviating an increase in the steering torque during such high-speed steering. FIG. 18 functionally illustrates an example of an electric power steering control apparatus according to the eighth embodiment of the present invention in which a field winding type motor is used as a steering assisting motor. In FIG. 18, the same or corresponding parts as those in FIGS. 2 and 13 are identified by the same symbols while omitting a detailed description thereof.
FIG. 19 is a flow chart for explaining the processing performed by the target field winding current correction section 100 h in the electric power steering control apparatus according to the eighth embodiment of the present invention.
In step S 60 , it is determined whether the vehicle speed detected by the vehicle speed sensor 6 is greater than a predetermined value, and when the vehicle speed is less than the predetermined value, the field current instruction value (If*) is adopted as the corrected field current instruction value (If**) in step S 65 , whereas when the vehicle speed is greater than the predetermined value, the control process advances to the processing in step 61 . Subsequently, in step S 61 , it is determined whether the steering torque detected by the torque sensor 3 is greater than a predetermined value, and when the steering torque is less than the predetermined value, the field current instruction value (If*) is adopted as the corrected field current instruction value (If**) in step S 65 , whereas when the steering torque is greater than the predetermined value, the control process advances to the processing in step S 62 .
In step S 62 , it is determined whether the armature current deviation (ΔIa) is greater than a predetermined value, and when the armature current deviation (ΔIa) is less than the predetermined value, the field current instruction value (If*) is adopted as the corrected field current instruction value (If**) in step S 65 , whereas when the armature current deviation (ΔIa) is greater than the predetermined value, the control process advances to the processing in step 63 . In step 63 , a corrected current value (Ida) is determined by referring to a table, which has been prepared in advance using the armature current deviation (ΔIa) as a parameter. Then in step S 64 , the field current instruction value is corrected by subtracting the corrected current value (Ida) from the field current instruction value (If*), and the thus corrected field current instruction value (If**) is supplied to the current control section 100 e.
As described in the foregoing, according to the present invention, current is controlled in such a manner that the magnetic field of the motor field magnet is weakened during high-speed steering in which the output torque of the motor decreases. As a result, a decrease in the motor output torque can be alleviated.
Moreover, in the case of an electric power steering control apparatus, an increase in the steering torque at the time of high-speed steering can be reduced, as illustrated in FIG. 20 for instance.
In addition, in the case of a steer-by-wire steering system, it is possible to improve the followability of an actual steering angle with respect to an operator's induced steering angle at the time of high-speed steering.
While the invention has been described in terms of preferred embodiments, those skilled in the art will recognize that the invention can be practiced with modifications within the spirit and scope of the appended claims.
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A steering control apparatus is provided which is capable of alleviating a decrease in the output torque of a motor during high-speed steering. The steering control apparatus includes a motor 5 , a motor current instruction value generation section 100 a , 100 b for generating a current instruction value for the motor 5 , a motor current detection section 102 a , 102 b for detecting a current flowing through the motor 5 , wherein the motor 5 is driven to rotate based on at least the current, which flows through the motor 5 , and the current instruction value. The motor current instruction value generation section includes a correction section 100 b for correcting the current instruction value which controls the magnetic field of a field magnet of the motor 5 , the correction section being operable to correct the current instruction value for controlling the magnetic field of the field magnet of the motor 5 when a steering speed is fast.
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BACKGROUND OF THE INVENTION
The present invention relates to a road traffic sign formed on a road so as to be visually recognizable by a passer-by or a driver of a running vehicle.
To assure safety of road traffic, various road traffic signs are drawn on the road surface. When these road traffic signs are visually recognized by the passers-by and drivers, caution is alerted and safety is assured. Hitherto, these road traffic signs were generally characters and patterns drawn as a flat pattern, and it was not sufficient to alert attention to vehicles running at high speed, in particular, and these road traffic signs were often overlooked.
Accordingly, for vehicles running at high speed, by drawing lateral lines at equal intervals on the road surface, it was intended to cause the driver to recognize the sensation of speed and slow down the speed intentionally. In Great Britain, white zigzag lines are drawn at both sides of the road surface near the pedestrian crossing, and it is intended so that the driver may recognize the presence of pedestrian crossing and slow down the speed intentionally. Such road traffic signs can enhance the visual recognition, but, same as in the above prior art, it is still likely to be overlooked because the form of sign is a flat pattern recognition.
Accordingly, instead of the road traffic sign for flat pattern recognition, it is also attempted to bulge part of the road surface, so that the bulged part may be recognized to slow down the speed forcedly. In this method, however, if the vehicle rides over the bulge at high speed, it causes noise, and is accompanied by danger. It also needs tremendous labor in the work for bulging part of the road surface.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view showing a constitution of an embodiment of the invention.
FIG. 2 is a plan view showing a form of each section in FIG. 1.
FIG. 3 is a plan view showing a constitution of other embodiment of the invention.
FIG. 4 is a plan view showing a form of each section in FIG. 3.
FIG. 5 is a plan view showing a state of forming a sign pattern shown in FIG. 3 on a road surface.
FIG. 6 is a plan view showing other state of forming a sign pattern shown in FIG. 3 on a road surface.
FIG. 7 is a plan view showing a constitution of a different embodiment of the invention.
FIG. 8 is a plan view showing a state of forming the sign pattern shown in FIG. 1 on a road surface.
FIG. 9 is a plan view showing a constitution of other different embodiment of the invention.
FIG. 10 is a plan view showing a constitution of a further different embodiment of the invention.
FIG. 11 is a plan view showing a constitution of a still different embodiment of the invention.
FIG. 12 is a plan view showing a constitution of still other different embodiment of the invention.
FIG. 13 is a plan view showing a constitution of a still further different embodiment of the invention.
FIG. 14 is a plan view showing a constitution of another embodiment of the invention.
FIG. 15 is a plan view showing a constitution of still another embodiment of the invention.
OBJECT AND SUMMARY OF THE INVENTION
It is hence an object of the invention to enhance the visual recognition of road traffic sign, prevent danger in road traffic, and ensure smooth traffic, by presenting a road traffic sign composed of a solid pattern having shades as visual image.
To achieve the object, the road traffic sign of solid graphic pattern of the invention is a road traffic sign composed of a marking pattern divided in plural sections, formed tightly on the road, in which adjacent sections differ in lightness from each other, so that the solid image of the visual image of the marking pattern may be recognized. Herein, the solid image of the visual image includes, for example, convex and concave shape, and is any one in which a three-dimensional image can be recognized. In this constitution, adjacent sections mutually have a lightness difference of Munsell value of 1 or more, and the lightness of each section is selected in a lightness of two to four stages individually set at different Munsell values. Herein, by setting of lightness in two to four stages, the process for forming a solid pattern to be drawn is easy and practical when the number of plane portions is two to four. In manufacture of this road traffic sign, for example, by preparing sheet pieces differing in lightness in two to four stages, they can be used generally.
Or, adjacent sections may be colored in the hue mutually different in lightness.
In this constitution, since the adjacent sections are mutually different in lightness, shades are expressed in the marking pattern, and in this marking pattern, a solid image can be recognized as visual image. Moreover, in the constitution in which the lightness difference of adjacent sections are set at 1 or more of Munsell value and the lightness of each section is selected in the lightness of two or four stages individually set at different Munsell values, enough and sufficient shades to be recognized as solid image can be formed, and the visual recognition is enhanced. It is the most preferred to employ the lightness difference of adjacent sections being set at 2 or more Munsell value. In such a case, a more solid visual image can be obtained. Moreover, when adjacent sections are colored in the hue individually different in lightness, a more solid visual image can be obtained by the difference in hue of sections, and the visual recognition is further improved. Still more, in the road traffic sign of the invention, if the vehicle rides over this road traffic sign, although it is recognized as a solid image visually, it is not actually bulged up, and hence it is not accompanied by danger.
In a preferred embodiment of the invention, the shape of the material for composing the sections may include sheet, plate, block, coat film, etc.
The sheet material may be obtained by curing rosin resin, petroleum resin, other hot-melt, epoxy resin, polyester resin, other synthetic resin, or acrylic compound. By adhering such sheet materials on the road surface, the marking pattern is formed.
Plate and block materials may include artificial stone concrete, concrete, brick, tile, glass, asphalt, metal, synthetic resin, and ceramics. This metal materials may include color iron and steel sheet and alminum plate. These materials are partly buried in the road, and partly exposed.
As the coat film materials, for example, water-based paint, oil-based paint, colored white cement, colored asphalt, colored emulsifier, material used as the above sheet material, other sheet form material and other paints are used. In this constitution, the paint is applied on the road surface. In the constitution of such coat film, the road sign can be installed relatively at low cost, and it does not require huge machinery for installation, and hence the installation is easy.
Furthermore, these materials may be mixed with recursive reflection material such as glass beads, or light reserve material such as strontium aluminate and zinc sulfide. In the composition blended with such recursive reflection material or light reserve material, a sufficient lightness may be maintained at night only by a slight illumination or headlight, and the visual recognition is not lowered.
Incidentally, when drawing a marking pattern on the road, it is preferred to employ a stereographic technique such as conformal projection and gradient method. In such a case, an accurate solid image is obtained, and the reliability as solid image is high.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, preferred embodiments of the invention are described in detail below.
FIG. 1 is a plan view showing a constitution of an embodiment of the invention, and FIG. 2 is a plan view showing a form of each section in FIG. 1.
A road traffic sign 2 of solid graphic pattern in the embodiment of the invention is arranged on a road R in a row in a vertical direction to the running (passing) direction on the road R. This road traffic sign 2 is composed of plural marking patterns 3 . . . 3, and white linking patterns 4 . . . 4 interposed in gaps of the respective marking patterns 3 . . . 3. The patterns are composed of sheet pieces, and in the marking pattern 3, a prismoid is formed as a visual image. This prismoid is composed of a sheet piece 1a forming the left side in white color (Munsell value about 9), a sheet piece 1b forming the top side in yellow color (Munsell value about 6), a sheet piece 1c forming the front side in red color (Munsell value about 5), and a sheet piece 1d forming the right side in brown color (Munsell value about 3). The lightness of the sheet pieces 1 is highest in white, being followed by yellow, red and brown in this order. In this marking pattern 3, a solid image is formed in the arrangement in which the lightness is highest at the left side, and gradually becomes darker in the top side, front side, and right side, and the lightness difference between sheet pieces can be recognized as the shade conforming to the shade drawing technique. That is, in this solid image, the ray of light is emitted from above the left front side, and looks darker in the sequence of the top side, front side and right side, and since the lightness difference of the adjacent sheet pieces of these sheet pieces 1a, 1b, 1c, 1d is 1 or more in Munsell value, so that a sufficient shade recognized as solid image is expressed. Incidentally, as the lightness difference becomes smaller, it is harder to be recognized as shade, and the boundary value is about 1 in Munsell value, and hence the lightness difference is required to be 1 or more of Munsell value.
As such sheet piece materials, those obtained by curing rosin resin, petroleum resin, other hot-melt, epoxy resin, polyester resin, other synthetic resin, or acrylic compound may be used. Furthermore, these materials may be mixed with recursive reflection material such as glass beads, or light reserve material such as strontium aluminate and zinc sulfide. In the composition blended with such recursive reflection material or light reserve material, a sufficient lightness may be maintained at night only by a slight illumination or headlight, and the visual recognition is not lowered. By adhering such sheet materials on the road surface, the marking pattern is formed.
This sheet piece 1 may have only a lightness difference such as white, gray and black and may not have hue, but as in the above constitution, when plural sheet pieces 1a, 1b, 2c, 1d are colored in hues of different lightness degrees, the difference of sides will be more clear and it is easier to be recognized three-dimensionally. The road traffic sign 2 shown in FIG. 1 is composed of four sides, that is, left side, top side, front side, and right side, and the sheet pieces 1a, 1b, 1c, 1d are set in four stages of lightness. In the embodiment, the sheet piece 1 is composed of the same number of sheet pieces 1 as the number of sections for forming a solid pattern, but not limited to this, to express the shade more precisely, one section may be composed of plural sheet pieces.
Thus, in the structure shown in FIG. 1, plural marking patterns 3 . . . 3 are formed on the road in a row in a direction vertical to the running direction, and these marking patterns 3 . . . 3 are linked with a white linkage sheet 4 in order to form a stop-line, but this linkage sheet 4 may be omitted.
The road traffic sign 2 of solid graphic pattern is not limited to the composition composed of four sides, but as shown in FIG. 3, it may be colored in different hues in three stages of lightness, or as shown in FIG. 4, three sheet pieces 6a, 6b, 6c may be disposed on the left slope, right slope, and front side to compose marking patterns 5 . . . 5. These sheet pieces 6a, 6b, 6c are colored respectively in white (Munsell value about 9), blue (Munsell value about 3), and yellow (Munsell value about 6), and a solid pattern of a triangular shape in vertical section is formed on the whole. That is, in the marking patterns 5 . . . 5 formed on the sheet piece 6a of the highest lightness, yellow sheet piece 6b of the middle, and blue sheet 6c of the lowest, a solid pattern composed of the left slope of the highest lightness, and front side and right slope of the second and third lightness is formed, and this lightness difference is recognized as shade, and this shade becomes darker to the front side and right slope, and this solid pattern is recognized to be illuminated from the left front upper side of the marking patterns 5 . . . 5 in the diagram.
Thus, in the structure shown in FIG. 3, same as in FIG. 1, the marking patterns 6 . . . 6 are formed on the road in a row in a direction vertical to the running direction, and they are linked with a white linkage sheet 4 to form a stop-line, but the linkage sheet piece 4 may be omitted.
The example of arrangement using the marking pattern 6 in FIG. 3 is not limited to a lateral row, as mentioned above, but, for example, two-rows may be arranged laterally as shown in FIG. 5. In this case, as compared with one lateral row, the visual recognition is enhanced, and the marking effect is greater.
FIG. 6 shows a constitution of a different embodiment. In this example, the marking pattern 6 shown in FIG. 3 is arranged in plural pieces to the right and left as shown in FIG. 6, and this road traffic sign 61 urges the driver to run in an S-curve so as to avoid these marking patterns 6 . . . 6. In such arrangement, the lanes may be changed as required.
FIG. 7 shows a constitution of other different embodiment. In this example, the marking pattern 6 shown in FIG. 3 is arranged as in FIG. 7, and the road traffic sign 62 is composed so as to be recognized three-dimensionally from both the running lane and the opposite lane of the road R. In this example, plural marking patterns 6 are arranged in each lane in a row in mutually reverse directions in the running lane and opposite lane, and are linked with a white linkage sheet 4 so as to mark stop-lines, and further by arranging sheet pieces 6d of yellow (Munsell value about 6) in inverted triangular shape before the linkage sheet 4, this triangular marking pattern 6 appears floating on the road R. Therefore, for the driver, this road traffic sign 62 is more easily recognized visually, and the visual recognition is enhanced.
FIG. 8 shows a constitution of a further different embodiment. In this example, the marking pattern 3 shown in FIG. 1 is arranged as in FIG. 8, so that the road traffic sign 31 can be recognized three-dimensionally from both the running lane and the opposite lane of the road R. In this example, plural marking patterns 3 are arranged in each lane in a row in mutually reverse directions in the running lane and opposite lane, and are linked with a white linkage sheet 4 so as to mark stop-lines. The constitution of this road traffic sign 31 is, same as in the preceding embodiment, high in visual recognition.
Furthermore, FIG. 9 shows a constitution of a still different embodiment. In this example, the left side and front side are formed of sheet pieces 7b of red (Munsell value about 5), and the top side is formed of a sheet piece 7a of white (Munsell value about 9) to compose square columnar marking patterns 7 . . . 7, and a plurality thereof are formed on the road in a row in a direction vertical to the running direction, thereby marking stop-lines.
As such square columnar marking pattern, still more, as shown in FIG. 10, square columnar marking patterns 8 may be arranged on the road R so as to be recognized three-dimensionally from both the running lane and the opposite lane. This square columnar marking pattern 8, when seen from the direction of arrow X1, is composed of a sheet piece 8a forming the top side in white (Munsell value about 9), a sheet piece 8b forming the left side in red (Munsell value about 5), and a sheet piece 8c forming the right side in yellow (Munsell value about 6). At the nearer side, a sheet piece 8d in white (Munsell value about 9) is formed as a linkage sheet for linking these plural marking patterns 8 . . . 8. On the other hand, when seen from the opposite lane confronting the running lane in the direction of arrow X1, that is, from the direction of arrow X2, the sheet piece 8a of this constitution forming the top side forms a linkage sheet, and the linkage sheet 8d forms the top side. Thus, the marking patterns 8 . . . 8 arranged in a row for marking the stop-line of the road R are composed of sheet pieces 8a, 8b, 8c, 8d having different lightness degrees, as mentioned above, in the directions of both running lane and opposite lane, so that the square columnar solid shape can be recognized visually.
As the constitution for arranging a plurality of marking patterns, a modified example as shown in FIG. 12 may be also applied.
This road traffic sign 12 is composed to express the median strip of the road R. A plurality of square columnar solid patterns composed of a sheet piece 12a in white (Munsell value about 9) formed on the top side, a sheet piece 12b in yellow (Munsell value about 6) formed on the left side, and a sheet piece 12c in red (Munsell value about 5) formed on the right side are arranged continuously, and a continuous sheet 12b 0 consecutive to the left side, and a continuous sheet 12c 0 consecutive to the right side are arranged continuously.
As the constitution for expressing such median strip of the road R, other example is shown in FIG. 11.
Sheet pieces 11a 1 , 11a 2 , 11a 3 white (Munsell value about 9) are arranged on the top side, and sheet pieces 11b 1 , 11b 2 , 11b 3 in blue (Munsell value about 3) are arranged on the right side. In this constitution, the road traffic sign 11 is recognized as a solid figure bulged up on an X-form in the state as if illuminated from the left side in the diagram.
Further, FIG. 13 shows a constitution of another different embodiment. In this road traffic sign 13, to express the intersection on the road R, a sheet piece 13a in white (Munsell value about 9) is formed on the top side, and sheet pieces 13b 1 , 13b 2 , 13b 3 in blue (Munsell value about 3) are formed on the sides, thereby forming the road traffic sign 13 in a cross form. By the arrangement of the sheet pieces 13a, 13b 1 , 13b 2 , 13b 3 for forming the road traffic sign 13 with a lightness difference, the road traffic sign 13 is recognized as a bulged solid cross form in the state as if illuminated from the right front upper side in the diagram.
The above embodiments refer to the visual image of solid shape in convex form, but such solid shape may be also a visual image in concave form.
Embodiments shown in FIG. 14 and FIG. 15 relate to visual images looking as if grooves were formed in the road surface.
A road traffic sign 14 shown in FIG. 14 is formed along the edge of road R, whose inner space is rectangularly hollowed to be divided into three sections, and is composed of a sheet piece 14b in blue (Munsell value about 3) and a sheet piece 14c in sky-blue (Munsell value about 7) as two of the three sections and a sheet piece 14a in white (Munsell value about 9) arranged around the rectangle. A divided section 14d is the surface of the road R itself, which is composed of asphalt. By disposing a plurality of thus constituted road traffic signs 14, a visual image recognizing a state of forming of plural grooves is obtained in the edge portion along the running lane in the road R. As a constitution for obtaining such concave form solid image, further, a constitution as shown in FIG. 15 may be considered. This road traffic sign 15 is formed along the edge of the road R same as in FIG. 14, and is composed of a sheet piece 15b of parallelogram in white (Munsell value about 9) and a sheet piece 15a of parallelogram in blue (Munsell value about 3). The sheet piece 15a, having a shape formed as being deviated in one direction to the sheet piece 15b, is adjacent to two sides adjoined each other of the sheet piece 15b of parallelogram. By disposing a plurality of such road traffic signs 15, same as in FIG. 14, plural concave solid images formed in the edge portion along the running lane of the road R can be visually recognized.
The road traffic signs in solid pattern formed by disposing plural sheet pieces are not limited to the above-mentioned linear and geometric patterns only, but may be expressed in characters, curved shapes or other solid figures.
When using such sheet pieces, they are adhered on the road to form the marking patterns. Such sheet material may be obtained by curing hot-melt type such as rosin resin and petroleum resin, or epoxy resin, polyester resin, or acrylic compound. Furthermore, these sheet materials may be mixed with recursive reflection material such as glass beads, or light reserve material, and in the composition blended with such recursive reflection material or light reserve material, a sufficient lightness may be maintained at night only by a slight illumination or headlight, and the visual recognition is not lowered.
In the illustrated examples, each divided section the marking pattern is formed of a sheet piece, but the shape of the material for composing the sections may be either plate or block. When using materials of such shape, they may be partly buried in the road, and partly exposed. As the shape of the material for composing sections, moreover, a coat film may be used. The coat film is formed by applying a paint on the road.
As plate and block materials, artificial stone concrete, concrete, brick, tile, glass, asphalt, metal, synthetic resin, and ceramics may be properly used. This metal materials may include color iron and steel sheet and alminum plate.
As the material for forming a coat film, paints such as water-based paint such as acrylic emulsion, oil-based paint such as carpenter's paint, and colored matter such as white cement maybe used.
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The following constitution is employed for enhancing the visual recognition of a road traffic sign by presenting a road traffic sign composed of a solid pattern having shades as visual image. A marking pattern divided into plural sections is tightly formed on the road, and the adjacent sections are mutually different in lightness, so that, in the road traffic sign of the invention, a solid figure is recognized as the visual image of the marking pattern. Herein, the adjacent sections have a lightness difference of 1 or more in Munsell value, and the lightness of each section is selected at lightness in two to four stages set at mutually different Munsell values. Moreover, when the adjacent sections are colored in hues mutually different in lightness, a more solid visual image will be obtained due to the difference in hue among the sections.
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COPYRIGHT NOTICE
[0001] A portion of the disclosure of this patent document contains material, which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.
FIELD OF THE INVENTION
[0002] The present invention relates to a method of analyzing additives in an electroplating bath. More particularly, the present invention relates to a method of analyzing at least two inhibitors simultaneously in an electroplating bath.
BACKGROUND
[0003] Electrodeposition is a frequently-used method to deposit different conductive metals into vias for forming electrical connections. Electroplating baths for electrodeposition of metal are typically aqueous solutions comprising metal salts, ionic electrolytes, and myriad additives like accelerators (brighteners), suppressors levelers, etc. The additives play key roles in electrodeposition since inappropriate species or concentrations may lead to voids, insufficient filling, and non-uniform deposit, and such defects can generate adverse effects to the devices, leading to great loss during mass production. For example, FIG. 1A-B show a via with poor filling quality at inappropriate leveler concentration, and another via with good filing quality at appropriate leveler concentration respectively.
[0004] As electrodeposition is commonly used for fabrication of electronic components and devices, reliable operation of electroplating baths in a manufacturing process need employ suitable analytical methods for determining the appropriate concentrations of the additives. These analytical methods are often used to determine the concentrations of species in the bath during operation, so as to provide on-line feedback control, and adjust the amount of additive for maintaining concentrations within pre-determined limits as shown in FIG. 2 .
[0005] U.S. Pat. No. 6,572,753 provides a method for analysis of three organic additives in an acid copper plating bath. Cyclic voltammetric stripping (CVS) methods are used to measure the concentrations of the suppressor and anti-suppressor based on the effects of these additives on the copper electrodeposition rate. The method uses measurements of the copper electrodeposition rate to determine the concentration of the leveler additive. The other two additives are included in the measurement solution at concentrations determined to provide the optimum compromise between minimal interference, high sensitivity and good reproducibility for the leveler analysis. Nevertheless, the method provides only a single analysis for leveler.
[0006] U.S. Pat. No. 6,808,611 discloses an electro-analytical method for determining the concentration of an organic additive in an acidic or basic metal plating bath using an organic chemical analyzer. The method includes preparing a supporting-electrolyte solution, preparing a testing solution including the supporting-electrolyte solution and a standard solution, measuring an electrochemical response of the supporting-electrolyte solution using the organic chemical analyzer, and implementing an electro-analytical technique to determine the concentration of the organic additive in the plating bath from the electrochemical response measurements. However, the method provides merely a single analysis for leveler.
[0007] U.S. Pat. No. 7,186,326 discloses a method for measuring the concentrations of a suppressor additive and an anti-suppressor additive in a plating bath for electrodeposition of a metal. Suppressor and anti-suppressor additives in an acid copper sulfate plating bath are analyzed by the cyclic voltammetric stripping method without cleaning or rinsing the cell between the two analyses. The suppressor analysis is performed first and the suppressor concentration in the resulting measurement solution is adjusted to a predetermined value corresponding to full suppression. This fully-suppressed solution is then used as the background electrolyte for the anti-suppressor analysis. However, the method provides only a sequential analysis for suppressor and accelerator.
[0008] U.S. Pat. No. 7,384,535 provides a method for determining the quantity of both brightener and leveler in a metal plating bath. The method is able to improve the reproducibility of measuring brighteners and levelers in electroplating baths. Nevertheless, the method provides just an integrated analysis for accelerator and leveler.
[0009] In actual mass production, two or more inhibitors such as a leveler and suppressor are frequently employed simultaneously in recipes for acquiring good via filling quality. However, the abovementioned methods fail to provide an integrated analysis for two or more inhibitors simultaneously. The problem raised here is that the sum of concentrations of at least two inhibitors is not equivalent to the measured concentration since the inhibitors provide other inhibiting effects when different inhibitors are mixed in a plating solution. For example, according to the prior art, when simply considering the equivalent concentration of two inhibitors by the sum of concentrations of each inhibitors, such calculation fails to provide the same results as the measured inhibitor concentration during the mass production, thereby leading to error occurred as shown in Table 1:
[0000]
TABLE 1
Actual S
Meas. S
Sample
concentration
concentration
Error
1
8 ml/L
11.5 ml/L
43.91%
2
5 ml/L
6.59 ml/L
38.13%
[0010] As shown in Table 1, the error generated can be as large as to be 43%. Such shortcoming makes manufacturer incapable of maintaining the appropriate additive concentration during the mass production, thereby substantially lowering the yield of products.
[0011] Therefore, there is an unmet need to provide an accurate, fast, and cost effective method for determining the concentrations of at least two inhibitors simultaneously in an electroplating bath during on-line feedback control for appropriate adjustment of the amount of additives in the bath to maintain the additive concentrations within pre-defined limits during device production.
SUMMARY
[0012] Accordingly, it is a first aspect of the presently claimed invention to provide a method of analyzing at least two inhibitors simultaneously in a plating bath using different electrical load approaches.
[0013] In accordance with an embodiment of the presently claimed invention, a method for determining additive concentrations of at least two inhibitors in a plating bath comprises: determining at least two inhibition factors of the at least two inhibitors by applying at least two electrical load conditions on at least two supporting solution respectively; determining equivalent suppressor concentrations of a testing solution under the at least two electrical load conditions respectively, wherein the testing solution comprises a virgin make-up solution and a portion of the plating bath, and the virgin make-up solution is an electrolyte solution comprising substances of the plating except the at least two inhibitors; and determining the additive concentrations of the at least two inhibitors based on the at least two inhibition factors and the equivalent suppressor concentrations of the testing solution under the at least two electrical load conditions.
[0014] In accordance with an embodiment of the presently claimed invention, the step of determining the at least two inhibition factors further comprises steps of:
(a) providing a first standard solution of a first inhibitor from the at least two inhibitors, having a known amount of the first inhibitor; (b) providing the virgin make-up solution; (c) measuring an original deposition rate (R 0 ) of the virgin make-up solution under a first electrical load condition from one of the at least two electrical load conditions; (d) adding a first volume of the first standard solution of the first inhibitor into the virgin make-up solution to form the supporting solution comprising the first volume of the first standard solution of the first inhibitor; (e) measuring a first deposition rate (R 1 ) of the supporting solution comprising the first volume of the first standard solution of the first inhibitor under the first electrical load condition to determine a first deposition rate ratio calculated by R 1 /R 0 ; (f) repeating the steps (d)-(e) by adding another volume of the first standard solution of the first inhibitor to determine another deposition rate ratio till obtaining a calibration curve of the first inhibitor; (g) repeating the steps (a)-(f) by using another standard solution of another inhibitor from the at least two inhibitors to obtain another calibration curve of the another inhibitor till obtaining all of the calibration curves of each of the at least two inhibitors; (h) determining calibrated concentrations of the at least two inhibitors for the first electrical load condition at a predetermined value of the deposition rate ratio based on the calibration curves of each of the at least two inhibitors; (i) repeating the steps (a)-(g) under another electrical load condition from the at least two electrical load conditions and determining another calibrated concentrations of another inhibitor for another electrical load condition at the predetermined value of the deposition rate ratio till obtaining all of the calibrated concentrations of each of the at least two inhibitors for each of the at least two electrical load conditions; and (j) determining the at least two inhibition factors for each of the at least two electrical load conditions based on all of the calibrated concentrations.
[0025] In accordance with an embodiment of the presently claimed invention, the step of determining the equivalent suppressor concentrations of the testing solution further comprises steps of:
(a) providing a volume of the virgin mark-up solution; (b) measuring an original deposition rate of the volume of the virgin mark-up solution (R 0 ′) under the first electrical load condition; (c) adding a first volume of the plating bath into the virgin mark-up solution to form the testing solution comprising the first volume of the plating bath; (d) measuring a first deposition rate (R 1 ′) of the testing solution comprising the first volume of the plating bath under the first electrical load condition to determine a first deposition rate ratio calculated by R 1 ′/R 0 ′; (e) repeating the steps (c)-(d) by adding another volume of the plating bath to determine another deposition rate ratio till obtaining an analysis curve of the plating bath solution for the first electrical load condition; (f) determining a volume of plating bath sample addition at the predetermined value of the deposition rate ratio for the first electrical load condition; (g) repeating steps (a)-(e) under another electrical load condition from the at least two electrical load conditions and determining another volume of plating bath sample addition for another electrical load condition at the predetermined value of the deposition rate ratio till obtaining all of the volumes of plating bath sample addition for each of the at least two electrical load conditions; and (h) determining the equivalent suppressor concentrations of the plating bath solution based on the volumes of plating bath sample addition of each of the at least two electrical load conditions, and the calibrated concentrations of each of the at least two electrical load conditions.
[0034] A second aspect of the presently claimed invention is to provide a computer-readable medium whose contents cause a computing system to perform the methods of the present invention.
[0035] The presently claimed invention provides an accurate, fast, and cost effective method for determining the concentrations of at least two inhibitors simultaneously in an electroplating bath during on-line feedback control for appropriate adjustment of the amount of additives to maintain the inhibitor concentrations within pre-defined limits during device production.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] Embodiments of the present invention are described in more detail hereinafter with reference to the drawings, in which:
[0037] FIG. 1A-B show two photos of a via with poor filling quality at inappropriate leveler concentration, and another via with good filing quality at appropriate leveler concentration respectively;
[0038] FIG. 2 is a graph showing additive concentrations monitored with time during mass production for maintaining appropriate additive recipe within a control limit;
[0039] FIG. 3 shows a process flow chart illustrating the steps of a method for analyzing two inhibitors simultaneously in a plating bath using two different potential range approach according to one embodiment of the presently claimed invention;
[0040] FIG. 4 shows a process flow chart illustrating the steps of determining two inhibition factors under two different plating potential ranges according to one embodiment of the presently claimed invention;
[0041] FIG. 5 shows cyclic voltammetric stripping (CVS) curves at potential range −0.23V to 1.57V for two supporting solutions with addition of suppressor solution and leveler solution respectively according to an embodiment of the presently claimed invention;
[0042] FIG. 6 shows cyclic voltammetric stripping curves at potential range −0.4V to 1.57V for two supporting solutions with addition of suppressor solution and leveler solution respectively according to an embodiment of the presently claimed invention;
[0043] FIG. 7 shows calibration curves of deposition rate ratio (R i /R o ) at the potential range of −0.23 to 1.57V for the supporting solutions with different suppressor concentrations, and different leveler concentrations respectively according to an embodiment of the presently claimed invention;
[0044] FIG. 8 shows calibration curves of deposition rate ratio (R i /R o ) at the potential range of −0.4 to 1.57V for the supporting solutions with different suppressor concentrations, and different leveler concentrations respectively according to an embodiment of the presently claimed invention;
[0045] FIG. 9 shows a process flow chart illustrating the steps of determining two equivalent concentrations of a testing solution under two plating potential ranges according to one embodiment of the presently claimed invention;
[0046] FIG. 10 shows cyclic voltammetric stripping curves at potential range −0.23V to 1.57V for two plating bath sample additions with unknown concentrations of additives according to an embodiment of the presently claimed invention;
[0047] FIG. 11 shows cyclic voltammetric stripping curves at potential range −0.4V to 1.57V for two plating bath sample additions with unknown concentrations of additives according to an embodiment of the presently claimed invention;
[0048] FIG. 12 shows sample analysis curves with deposition rate ratio versus volume of plating bath sample addition at potential range of −0.23 to 1.57V according to an embodiment of the presently claimed invention; and
[0049] FIG. 13 shows sample analysis curves with deposition rate ratio versus volume of plating bath sample addition at potential range of −0.4 to 1.57V according to an embodiment of the presently claimed invention.
DETAILED DESCRIPTION
[0050] In the following description, methods for analyzing at least two inhibitors simultaneously in a plating bath using different electrical load conditions are set forth as preferred examples. It will be apparent to those skilled in the art that modifications, including additions and/or substitutions may be made without departing from the scope and spirit of the invention. Specific details may be omitted so as not to obscure the invention; however, the disclosure is written to enable one skilled in the art to practice the teachings herein without undue experimentation.
[0051] As used herein, the term “inhibitor” refers to an additive for electroplating, which reduces deposition rate during electroplating.
[0052] As used herein, the term “inhibition factor” refers to a concentration ratio of two inhibitors when achieving the same inhibition effect on electroplating rate.
[0053] As used herein, the term “equivalent suppressor (S) concentration” refers to a nominal concentration value for mixed inhibitors equivalent to one of the mixed inhibitors. Such that various inhibitor concentrations are transferred into one equivalent S concentration.
[0054] FIG. 3 shows a process flow chart illustrating the steps of a method for analyzing two inhibitors simultaneously in a plating bath using two different potential ranges according to one embodiment of the presently claimed invention. The inhibitors are a leveler, L and a suppressor, S. In step 301 , a first L-to-S inhibition factor, α under a first plating potential range is determined. In step 302 , a second L-to-S inhibition factor, β is determined under a second plating potential range. In step 303 , a first equivalent suppressor concentration, γ p1 of a testing solution under the first plating potential range is determined. In step 304 , a second equivalent suppressor concentration, γ p2 of the testing solution under the second plating potential range is determined. In step 305 , a suppressor concentration, C S and a leveler concentration, C L in the plating bath are determined based on the first L-to-S inhibition factor, the second L-to-S inhibition factor, the first equivalent suppressor concentration, and the second equivalent suppressor concentration.
[0055] Accordingly, the suppressor concentration, C S and the leveler concentration, C L are calculated as follows:
[0000] C S +αC L =γ p1 (1)
[0000] C S +βC L =γ p2 (2)
[0056] Hence, there are:
[0000]
C
L
=
γ
p
1
-
γ
p
2
α
-
β
(
3
)
C
S
=
α
γ
p
1
-
β
γ
p
2
α
-
β
(
4
)
[0057] FIG. 4 shows a process flow chart illustrating the steps of determining the first and the second L-to-S inhibition factors under two different plating potential ranges according to one embodiment of the presently claimed invention. In step 401 , a volume of virgin make-up solution without additives and standard suppressor solution are prepared. The virgin make-up solution comprises all inorganic substance of the plating bath except the first and the second inhibitors, and the standard suppressor solution has a known concentration of the suppressor. In step 402 , the deposition rate (R 0 ) of the virgin make-up solution at a predetermined plating potential range is measured. In step 403 , a small volume of the standard suppressor solution is gradually added into the virgin make-up solution in multiple times to form multiple supporting solutions, and various deposition rates (R i ) of the supporting solutions having different volumes of the standard suppressor solutions are measured after each addition of the standard suppressor solution at the same plating potential range. In step 404 , all deposition rate ratios, calculated by R i /R 0 , are plotted versus the suppressor concentration to obtain a suppressor calibration curve. In step 405 , steps 401 - 404 are repeated by replacing the standard suppressor solution with a standard leveler solution to obtain a leveler calibration curve. In step 406 , at a predetermined deposition rate ratio, calibrated concentrations of the standard suppressor solution (C S cali ) and the standard leveler solution (C L cali ) are determined based on the suppressor and the leveler calibration curves for further determination of the L-to-S inhibition factor (α or β) at the predetermined plating potential range. In step 407 , steps 401 - 406 are repeated with another predetermined plating potential range to determine calibrated concentrations at another predetermined plating potential range.
[0058] Accordingly, the L-to-S inhibition factors for a first and a second plating potential ranges, α and β are calculated as follow:
[0000]
α
=
C
S
,
p
1
cali
C
L
,
p
1
cali
(
5
)
β
=
C
S
,
p
2
cali
C
L
,
p
2
cali
(
6
)
[0000] where C S,p1 cali is the calibrated concentration of the suppressor at the first plating potential range, C L,p1 cali is the calibrated concentration of the leveler at the first plating potential range, C S,p2 cali is the calibrated concentration of the suppressor at the second plating potential range, and C L,p2 cali is the calibrated concentration of the leveler at the second plating potential range.
[0059] According to an embodiment of the presently claimed invention, cyclic voltammetric stripping is used to apply different plating potential ranges, and measure the deposition rates for both of the virgin make-up solution and the supporting solutions with addition of different volumes of the inhibitors. Cyclic voltammetric stripping is an electrochemical technique commonly used for the measurement of organic additives in a plating bath. It is based on the effect that the additives have on the rate of electroplating. Regardless of the specific type of organic additive such as brightener, leveler, or grain refiner, the activity of the organic additive is reflected in the change of the plating rate. The analysis is conducted in an electrochemical cell using a three-electrode system, one of which is a platinum rotating disk electrode. During measurement, the potential of the platinum electrode is controlled by the instrument. The potential is scanned at a constant rate back and forth between negative and positive voltage limits. A small amount of metal from the plating bath is alternatively plated onto and stripped off the working electrode as the potential is changed. During the scan, the current at the working electrode is measured as a function of potential. As the activity of the additive affects the plating rate of the metal onto the electrode, the plating rate is determined by calculating the charge required to strip the metal off the working electrode. The relationship between the stripping charge and the activity of the additives is used to quantitatively measure the additives and their components.
[0060] FIG. 5 shows cyclic voltammetric stripping curves at a potential range of −0.23V to 1.57V for two supporting solutions with a suppressor and a leveler respectively according to an embodiment of the presently claimed invention. The curve with solid line for leveler is used for determining point A as shown in FIG. 7 . The curve with dotted line for suppressor is used for determining point B as shown in FIG. 7 . Similarly, FIG. 6 shows cyclic voltammetric stripping curves at a potential range of −0.4V to 1.57V for two supporting solutions with the suppressor and the leveler respectively according to an embodiment of the presently claimed invention.
[0061] By calculating the charge required to strip the metal off the working electrode, the deposition rates of R 0 and R i are determined for further determining the deposition rate ratio as calculated by R i /R 0 . FIG. 7 shows calibration curves of the leveler and the suppressor respectively at the potential range of −0.23 to 1.57V according to an embodiment of the presently claimed invention. FIG. 8 shows calibration curves of the leveler and suppressor at the potential range of −0.4 to 1.57V according to an embodiment of the presently claimed invention.
[0062] Once acquiring the calibration curves, the calibrated concentrations of the leveler and suppressor are determined. As shown in FIG. 7-8 , at the deposition rate ratio of 0.75, C S,p1 cali is determined as 0.5458 ml/L, and C L,p1 cali is determined as 0.6838 ml/L at the potential range of −0.23 to 1.57, while C S,p2 cali is determined as 0.8254 ml/L, and C L,p2 cali is determined as 0.9883 ml/L at the potential range of −0.4 to 1.57. By using the equations (4) and (5), the first inhibitor, a is calculated as 0.798, and the second inhibitor, β is calculated as 0.8352.
[0063] FIG. 9 shows a process flow chart illustrating the steps of determining the two equivalent suppressor concentrations of a testing solution under two plating potential ranges according to one embodiment of the presently claimed invention. In step 901 , a volume of virgin make-up solution (V 0 ) without additives, and a bath sample with unknown concentrations of the additives are prepared. In step 902 , the deposition rate (R 0 ′) of the virgin make-up solution at the predetermined plating potential range is determined. In step 903 , the bath sample is gradually added into the virgin make-up solution in multiple times to form multiple testing solutions, and various deposition rates R i ′ of the testing solutions having different volumes of bath sample after each addition of the bath sample at the same potential range are measured. In step 904 , all the deposition rate ratios, calculated by R i ′/R 0 ′, are plotted versus volume of addition to obtain a sample analysis curve at the predetermined plating potential range. In step 905 , at the predetermined deposition rate ratio, the corresponding volume of sample addition (V samp ) is determined based on the sample analysis curve, and hence the equivalent suppressor concentration is determined under the predetermined plating potential range. In step 906 , steps 901 - 905 are repeated under another predetermined plating potential range for determining another equivalent suppressor concentration.
[0064] Accordingly, the equivalent suppressor concentrations at the first and the second plating potential ranges, γ p1 and γ p2 are calculated as follows:
[0000]
γ
p
1
=
C
S
,
p
1
cali
(
V
0
+
V
samp
,
p
1
)
V
samp
,
p
1
(
7
)
γ
p
2
=
C
S
,
p
2
cali
(
V
0
+
V
samp
,
p
2
)
V
samp
,
p
2
(
8
)
[0000] where V samp,p1 and V samp,p2 are the volume of sample addition at the first and the second potential ranges.
[0065] FIG. 10 shows cyclic voltammetric stripping curves at potential range −0.23V to 1.57V for two plating bath sample additions with unknown concentrations of additives respectively according to an embodiment of the presently claimed invention. The curve with solid line is used for determining the point at sample addition # 1 in FIG. 12 . The curve with dotted line is used for determining the point at sample addition # 2 in FIG. 12 . Similarly, FIG. 11 shows cyclic voltammetric stripping curves at potential range −0.4V to 1.57V for two plating bath sample additions with unknown concentrations of additives respectively according to an embodiment of the presently claimed invention.
[0066] By calculating the charge required to strip the metal off the working electrode, the deposition rates of R 0 ′ and R i ′ are determined for further determining the deposition rate ratio, calculated by R i ′/R 0 ′. FIG. 12 shows sample analysis curves with deposition rate ratio versus volume of plating bath sample addition at potential range of −0.23 to 1.57V according to an embodiment of the presently claimed invention. FIG. 13 shows sample analysis curves with deposition rate ratio versus volume of plating bath sample addition at potential range of −0.4 to 1.57V according to an embodiment of the presently claimed invention.
[0067] Once acquiring the sample analysis curves, the volumes of sample addition are determined under different predetermined plating potential range. As shown in FIG. 12-13 , at the deposition rate ratio of 0.75, V samp,p1 is determined as 1.144 ml at the potential range of −0.23 to 1.57, and V samp,p2 is determined as 1.744 ml at the potential range of −0.4 to 1.57. By using the equations (7) and (8), the equivalent suppressor concentrations for the predetermined plating potential ranges, γ p1 and γ p2 are calculated as 12.4724 ml/L and 12.6577 ml/L.
[0068] Consequently, by using the equations (3) and (4), C L is calculated as 8.4771 ml/L, and C S is calculated as 4.9946 ml/L.
[0069] According to an embodiment of the presently claimed invention, the suppressor concentrations and the leveler concentrations determined by the method of present invention are shown in the Table 2 and 3 respectively:
[0000]
TABLE 2
Sample
Actual S (ml/L)
Meas. S (ml/L)
Err. S
1
8
8.4771
5.96%
2
5
4.8853
−2.29%
3
10
9.8446
−1.54%
[0000]
TABLE 3
Sample
Actual L (ml/L)
Meas. L (ml/L)
Err. L
1
5
4.9946
−0.11%
2
3
3.1727
5.74%
3
6
6.2107
3.51%
[0070] As shown in Table 2 and 3, when comparing the actual inhibitor concentration (obtained by the method of present invention) with the measured inhibitor concentration during production, the largest error generated by the present invention is merely about 5%, which is substantially lower that that of the prior art with about 49% as shown in Table 1. Hence nearly 90% of the error regarding the inhibitor concentration is reduced by the method of the present invention.
[0071] Accordingly, apart from using the cyclic voltammetric stripping to provide different plating potential ranges, other electrochemical analysis techniques, such as cyclic pulse voltammetric stripping, chronoamperometry, and chronopotentiometry, are applicable to apply electrical load conditions utilized for determining deposition rates. Different electrochemical analysis techniques have different loading modes. For example, the chronoamperometry provides plating current.
[0072] Accordingly, the present invention is not limited to analyzing two inhibitors simultaneously in an electroplating bath. Additive concentrations of more than two inhibitors can be effectively determined by the present invention.
[0073] According to an embodiment of the presently claimed invention, there are three inhibitors in a plating bath. The concentrations of the three inhibitors are calculated as follows:
[0000] C S +α ls C L +α zs C Z =γ p1 (9)
[0000] C S +β ls C L +β zs C Z =γ p2 (10)
[0000] C S +λ ls C L +λ zs C Z =γ p3 (11)
[0000] where C S , C L , C Z are concentrations for three inhibitors, S, L and Z respectively; α ls , α zs are inhibition factors of L and Z relative to S under the first potential range respectively; β ls , β zs are inhibition factors of L and Z relative to S under the second potential range respectively; λ ls , λ zs are inhibition factors of L and Z relative to S under the third potential range respectively; and γ p1 , γ p2 , γ p3 are equivalent concentrations of inhibitor S under the three different potential ranges respectively.
[0074] Hence, there are
[0000]
C
L
=
(
β
zs
-
λ
zs
)
(
γ
p
1
-
γ
p
2
)
-
(
α
zs
-
β
zs
)
(
γ
p
2
-
γ
p
3
)
(
β
zs
-
λ
zs
)
(
α
ls
-
β
ls
)
-
(
α
zs
-
β
zs
)
(
β
ls
-
λ
ls
)
(
12
)
C
Z
=
(
β
ls
-
λ
ls
)
(
γ
p
1
-
γ
p
2
)
-
(
α
ls
-
β
ls
)
(
γ
p
2
-
γ
p
3
)
(
β
ls
-
λ
ls
)
(
α
zs
-
β
zs
)
-
(
α
ls
-
β
ls
)
(
β
zs
-
λ
zs
)
(
13
)
C
S
=
γ
p
1
-
α
ls
C
L
-
α
zs
C
Z
(
14
)
[0075] The embodiments disclosed herein may be implemented using general purpose or specialized computing devices, computer processors, or electronic circuitries including but not limited to digital signal processors (DSP), application specific integrated circuits (ASIC), field programmable gate arrays (FPGA), and other programmable logic devices configured or programmed according to the teachings of the present disclosure. Computer instructions or software codes running in the general purpose or specialized computing devices, computer processors, or programmable logic devices can readily be prepared by practitioners skilled in the software or electronic art based on the teachings of the present disclosure.
[0076] In some embodiments, the present invention includes computer storage media having computer instructions or software codes stored therein which can be used to program computers or microprocessors to perform any of the processes of the present invention. The storage media can include, but are not limited to, floppy disks, optical discs, Blu-ray Disc, DVD, CD-ROMs, and magneto-optical disks, ROMs, RAMs, flash memory devices, or any type of media or devices suitable for storing instructions, codes, and/or data.
[0077] The foregoing description of the present invention has been provided for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many modifications and variations will be apparent to the practitioner skilled in the art.
[0078] The embodiments were chosen and described in order to best explain the principles of the invention and its practical application, thereby enabling others skilled in the art to understand the invention for various embodiments and with various modifications that are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the following claims and their equivalence.
|
The presently claimed invention provides an accurate, fast, and cost effective method for determining the additive concentrations of at least two inhibitors simultaneously in an electroplating bath by using different electrical load conditions. The method of the present invention is able to determine additive concentrations of different inhibitors effectively during on-line feedback control for adjusting the amount of additives in the electroplating bath to maintain the additive concentrations within pre-defined limits during device production.
| 2
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a monoazo metal compound, a composition comprising a monoazo metal compound, a toner for developing electrostatic images, a charge control agent for controlling or stabilizing the amount of charges of said toner, a powdery paint for electrostatic painting and a charge enhancer for enhancing the charge of said powdery paint.
2. Description of the Prior Art
In copying machines, printers and other instruments based on electrophotography, various toners containing a coloring agent, a fixing resin and other substances are used to visualize the electrostatic latent image formed on the photoreceptor having a light-sensitive layer containing an inorganic or organic photoconductive substance.
Toner chargeability is a key factor in electrostatic latent image-developing systems. Thus, to appropriately control or stabilize the amount of toner charge, a charge control agent providing a positive or negative charge is often added to the toner.
Of the conventional charge control agents in actual application, those providing a positive charge for a toner include basic dyes such as nigrosine dyes and triarylmethane dyes, and quaternary ammonium salts, i.e. electron donors. Charge control agents providing a negative charge for a toner include 2:1 type metal complexes of azo dyes and metal complexes of aromatic hydroxycarboxylic acids such as alkylsalicylic acids.
However, most metal complexes of azo dye structure used as charge control agents are usually unstable; for example, they are likely to be decomposed or deteriorated to lose their expected charge control capability when exposed to mechanical friction or impact, temperature or humidity changes, electric impact, light irradiation, etc. Also, even such metal complexes possessing a practically applicable charge providing property are often problematic as to charge stability or often contain impurity chemicals lacking charge control effect due to differences in production method etc., posing many problems regarding quality stability, reliability and other aspects.
Also, to improve paint adhesion efficiency in electrostatic powder painting, there have been attempts to apply charge control agents that have traditionally been used to control or enhance the charge of toners for developing electrostatic images.
Such attempts include an electrostatic powdery paint containing a resin polymer of an azine dye Japanese Patent Unexamined Publication No. 67563/1985!, a resin powder composition for electrostatic painting containing a charge enhancer like a metal-containing complex salt compound (Japanese Patent Unexamined Publication No. 75077/1988), and a powdery paint composition containing a quaternary ammonium salt as a charge control agent or charge enhancer (Japanese Patent Unexamined Publication No. 212563/1990).
However, these electrostatic powdery paints remain to be further improved in terms of environmental stability and heat resistance and durability under high-temperature conditions during powder painting.
Among charge control agents or charge enhancers capable of resolving these problems are the metal complex salt compounds of monoazo dyes, having the following structures: ##STR2## wherein A represents H, an alkali metal, an amine or the like.
Such chromium complex salt dyes are what is called 2:1 type azo-metal complex salt dyes wherein 2 molecules of a monoazo dye are coordinated to 1 trivalent chromium atom, and remain to be further improved as to chargeability stability and reliability.
The object of the present invention is to provide a metal compound of new chemical structure excellent in charge control or charge-enhancing property, heat resistance and light fastness; a charge control agent or charge enhancer that contains said metal compound as an active ingredient, that is good in dispersibility in resin and excellent in environmental resistance (stability of charge control or charge-enhancing property to changes in temperature or humidity), storage stability (stability over time of charge control or charge-enhancing property) and durability (charge control or charge-enhancing property stability in frequently repeated use), and that does not affect toner fixability or offset property when used in toners; and a toner for developing electrostatic images and powdery paint for electrostatic painting of stable quality and high reliability.
SUMMARY OF THE INVENTION
A monoazo metal compound of the present invention, wherein 3 molecules of a monoazo compound having 2 metallizable --OH groups represented by formula II! or III! below are coordinated to 2 metal atoms (Met), is represented by the formula:
D.sub.3 (Met).sub.2 I!
wherein D represents a ligand based on a monoazo compound: ##STR3## wherein R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , R 9 and R 10 independently represent a hydrogen, a halogen, a nitro group, an alkyl or haloalkyl group having 1 to 20 carbon atoms, an aryl group having or not having nuclear substitution, an aralkyl group having or not having nuclear substitution, --SO 2 N(R 11 ) 2 (Each of the two R 11 groups represents a hydrogen, a lower alkyl group, an aryl group having or not having nuclear substitution, or an aralkyl group having or not having nuclear substitution. The two R 11 groups may be identical or not.), --N(R 12 ) 2 (Each of the two R 12 groups represent a hydrogen, a lower alkyl group, an aryl group having or not having nuclear substitution, an aralkyl group having or not having nuclear substitution, or an acyl group. The two R 12 groups may be identical or not.), or --CONH(R 13 ) (R 13 represents a hydrogen, a lower alkyl group, an aryl group having or not having nuclear substitution, or an aralkyl group having or not having nuclear substitution); 2 or more of R 1 through R 10 may bind together to form an aromatic or aliphatic ring, and ##STR4## wherein R 21 , R 22 , R 23 , R 24 , R 25 , R 26 , R 27 , and R 28 independently represent a hydrogen, a halogen, a nitro group, an alkyl or haloalkyl group having 1 to 20 carbon atoms, an aryl group having or not having nuclear substitution, an aralkyl group having or not having nuclear substitution, --SO 2 N(R 29 ) 2 (Each of the two R 29 groups represent a hydrogen, a lower alkyl group, an aryl group having or not having nuclear substitution, or an aralkyl group having or not having nuclear substitution. The two R 29 groups may be identical or not.), --N(R 30 ) 2 (Each of the two R 30 groups represent a hydrogen, a lower alkyl group, an aryl group having or not having nuclear substitution, an aralkyl group having or not having nuclear substitution, or an acyl group. The two R 30 groups may be identical or not.), or --CONH(R 31 ) (R 31 represents a hydrogen, a lower alkyl group, an aryl group having or not having nuclear substitution, or an aralkyl group having or not having nuclear substitution); 2 or more of R 21 through R 28 may bind together to form an aromatic or aliphatic ring.
Another monoazo metal compound of the present invention, wherein 6 molecules of a monoazo compound having 2 metallizable --OH groups represented by formula II! or III! above are coordinated to 4 metal atoms (Met), is represented by the formula:
D.sub.6 (Met).sub.4 IV!
wherein D represents a ligand based on a monoazo compound.
A composition of the present invention comprises 2 or 3 monoazo metal compounds selected from the group consisting of monoazo metal compounds represented by formula VI! below, monoazo metal compounds represented by formula VII! below, and monoazo metal compounds represented by formula VIII! below: ##STR5##
In formulas VI!, VII! and VIII!, R 1 through R 10 have the same definitions as those given above; 2 or more of R 1 through R 10 may bind together to form an aromatic or aliphatic ring.
In formula VIII!, A + represents a cation.
Another composition of the present invention comprises 2 or 3 monoazo metal compounds selected from the group consisting of monoazo metal compounds represented by formula IX! below, monoazo metal compounds represented by formula X! below, and monoazo metal compounds represented by formula XI! below: ##STR6##
In formulas IX!, X! and XI!, R 21 through R 28 have the same definitions as those given above; 2 or more of R 21 through R 28 may bind together to form an aromatic or aliphatic ring.
In formula XI!, A + represents a cation.
The charge control agent of the present invention, which is a charge control agent for controlling or stabilizing the chargeability of a toner for developing electrostatic images, contains an above-described monoazo metal compound of the present invention or an above-described composition of the present invention as an active ingredient.
The toner of the present invention for developing electrostatic images comprises an above-described monoazo metal compound of the present invention or an above-described composition of the present invention as a charge control agent, a coloring agent and a resin. The toner may comprise a single monoazo metal compound of the present invention or a plurality of monoazo metal compounds of the present invention.
The charge enhancer of the present invention, which is a charge enhancer for controlling or enhancing the amount of charges of a powdery paint for electrostatic painting, contains an above-described monoazo metal compound of the present invention or an above-described composition of the present invention as an active ingredient.
Also, the powdery paint of the present invention for electrostatic painting comprises an above-described monoazo metal compound of the present invention or an above-described composition of the present invention as a charge enhancer and a resin.
The monoazo metal compounds of the present invention and the compositions comprising them are excellent in heat resistance and light fastness because of their chemical binding property.
The charge control agent and charge enhancer containing a monoazo metal compound of the present invention as an active ingredient, and the charge control agent and charge enhancer containing a composition comprising a monoazo metal compound of the present invention as an active ingredient are good in dispersibility in resin and excellent in chargeability controlling or stabilizing property or charge amount controlling or enhancing property, environmental resistance, storage stability and durability, and do not affect toner fixability or offset property when used in toners.
Containing an above-described monoazo metal compound of the present invention or an above-described composition of the present invention as a charge control agent, the toner of the present invention for developing electrostatic images is excellent in chargeability, environmental resistance, storage stability and durability, good in fixability and offset property, capable of forming toner images of high quality, and highly reliable in terms of product quality stability.
Containing an above-described monoazo metal compound of the present invention or an above-described composition of the present invention as a charge enhancer, the powdery paint of the present invention for electrostatic painting is excellent in chargeability, environmental resistance, storage stability, durability and painting adhesion efficiency, capable of forming a paint film of high quality, and highly reliable in terms of product quality stability.
DETAILED DESCRIPTION OF THE INVENTION
The monoazo metal compound represented by formula VI! or IX! is identical to the monoazo metal compound represented by formula I! (D 3 (Met) 2 ); the monoazo metal compound represented by formula VII! or X! is identical to the monoazo metal compound represented by formula IV! (D 6 (Met) 4 ). The monoazo metal compound represented by formula VIII! or XI! is identical to the monoazo metal compound represented by the formula:
D.sub.2 (Met)!.sup.-.A.sup.+ XII!
wherein D represents a ligand based on a monoazo compound; A + represents a cation.
With respect to the above-described monoazo metal compounds, the metal atom (Met) is exemplified by trivalent atoms of metals such as chromium, iron and aluminum, and cobalt and nickel, with preference given to trivalent chromium, trivalent iron, and trivalent aluminum.
With respect to the above-described monoazo metal compounds, the substituents R 1 through R 10 and R 21 through R 28 are exemplified by:
hydrogen H!;
halogens such as Cl, Br, I and F;
nitro groups;
alkyl groups having 1 to 20 carbon atoms or haloalkyl groups having 1 to 20 carbon atoms, such as methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, sec-butyl, tert-butyl, n-octyl, tert-octyl, 2-ethylhexyl, n-decyl and dodecyl, preferably alkyl groups having 1 to 12 carbon atoms or haloalkyl groups such as the trifluoromethyl group;
aralkyl groups (including those subjected to nuclear substitution with lower alkyl groups etc.) such as benzyl, benzyls substituted by lower alkyls (the term "lower alkyl" as used herein means an alkyl having 1 to 4 carbon atoms), phenylethyl, phenylpropyl, naphthylmethyl and naphthylethyl; aryl groups (including those subjected to nuclear substitution with lower alkyl groups or halogens) such as phenyl, naphthyl, phenyls substituted by lower alkyls, naphthyls substituted by lower alkyls, halogenated phenyls and halogenated naphthyls; --SO 2 N(R 11 ) 2 groups and --SO 2 N(R 29 ) 2 groups such as --SO 2 NH 2 , --SO 2 N(alkyl) 2 , --SO 2 NH(phenyl) and --SO 2 NH (benzyl) R 11 and R 29 independently represent a hydrogen, a lower alkyl group, an aryl group (including aryl groups subjected to nuclear substitution with lower alkyl groups or halogens) or an aralkyl group (including aralkyl groups subjected to nuclear substitution with lower alkyl groups etc.)!;
--N(R 12 ) 2 groups and --N(R 30 ) 2 groups such as --NH 2 , --N(alkyl) 2 , --NH(phenyl), --NH(benzyl) and --NH(acetyl) R 12 and R 30 independently represent a hydrogen, a lower alkyl group, an aryl group (including aryl groups subjected to nuclear substitution with lower alkyl groups or halogens), an aralkyl group (including aralkyl groups subjected to nuclear substitution with lower alkyl groups etc.), or an acyl group!; and
--CONH(R 13 ) groups and --CONH(R 31 ) groups such as --CONH 2 , --CONH(alkyl), --CONH(phenyl) and --CONH(benzyl) R 13 and R 31 independently represent a hydrogen, a lower alkyl group, an aryl group (including aryl groups subjected to nuclear substitution with lower alkyl groups or halogens) or an aralkyl group (including aralkyl groups subjected to nuclear substitution with lower alkyl groups etc.)!.
With respect to R 1 through R 4 above, it is preferable that 1 or 2 thereof be Cl or nitro groups (if two are such, they may be identical or not), because a good charge-providing property is obtained. The same applies to R 21 through R 24 .
As R 5 and R 25 above, hydrogen H! or an amide group represented by formula V! below is preferred: ##STR7## wherein (R 14 )0-2 means 0 to 2 substituents; R 14 represents a halogen such as Cl, Br, I or F, a lower alkyl group such as methyl or ethyl, or an alkoxy group having 1 to 4 carbon atoms, such as methoxy or ethoxy.
As R 6 through R 10 and R 26 through R 28 above, hydrogen H!; halogens such as Cl, Br, I and F; alkyl groups having 1 to 20 carbon atoms or haloalkyl groups having 1 to 12 carbon atoms, such as methyl, ethyl, propyl, isopropyl, butyl, sec-butyl, tert-butyl, amyl, octyl, tert-octyl and dodecyl; and --N(R 12 ) 2 and --N(R 30 ) 2 groups such as --NH 2 , --N(alkyl) 2 , --NH(phenyl), --NH(benzyl), --NH(acetyl) and --NH(benzoyl) are preferred. More preferably, R 6 through R 10 or R 26 through R 28 are all hydrogen H!, or 1 or 2 of R 6 through R 10 are halogens, alkyls or --N(R 12 ) 2 (if two are such, they may be identical or not) and 1 or 2 of R 26 through R 28 are halogens, alkyls or --N(R 30 ) 2 (if two are such, they may be identical or not).
With respect to formulas VIII!, XI! and XII!, A + is exemplified by cations such as H + , alkali metal ions, NH 4 + and organic amine ammonium.
The monoazo compound corresponding to the ligand D in each of the above monoazo metal compounds is exemplified by, but not limited to, the following example monoazo compounds (1) through (19): ##STR8##
A metallizable monoazo compound represented by formula II! or III! can be obtained by diazotization coupling reaction.
A monoazo metal compound of the present invention and a composition of the present invention can be obtained by reacting a metallizable monoazo compound represented by formula II! or III! with a metallizing agent in water and/or organic solvent (preferably in an organic solvent).
Generally, the reaction product formed in an organic solvent can be separated by dispersing it in an appropriate amount of water, collecting the resulting precipitate by filtration, washing it with water, and drying it.
Organic solvents useful for the above-described metallizing reaction include water-soluble organic solvents, including alcohol-series, ether-series and glycol-series organic solvents such as
methanol,
ethanol,
ethylene glycol monomethyl ether,
ethylene glycol monoethyl ether,
propylene glycol monomethyl ether,
ethylene glycol dimethyl ether (monoglyme),
diethylene glycol dimethyl ether (diglyme),
ethylene glycol diethyl ether,
triethylene glycol dimethyl ether (triglyme),
tetraethylene glycol dimethyl ether (tetraglyme),
ethylene glycol and
propylene glycol;
and aprotic polar solvents such as
N,N-dimethylformamide,
N,N-dimethylacetamide,
N-methyl-2-pyrrolidone and
dimethyl sulfoxide. The preferable solvents are ethylene glycol monomethyl ether (methyl cellosolve), ethylene glycol monoethyl ether (ethyl cellosolve) and ethylene glycol.
The amount of organic solvent used, not subject to limitation, is normally 2 to 5 parts by weight per part by weight of the monoazo compound (dye) used as the ligand.
Preferable metallizing agents include chromium compounds such as chromium formate, chromium sulfate, chromium chloride and chromium nitrate; iron compounds such as ferric chloride, ferric sulfate and ferric nitrate; and aluminum compounds such as aluminum sulfate and basic aluminum acetate.
The amount of metallizing agent used is normally 1/3 to 2 atomic equivalents, preferably 1/2 to 2/3 atomic equivalents per mol of the monoazo dye used as the ligand.
Isolation of reaction products was difficult even when various chromatographies were attempted. With this in mind, the FD-MS technique, known to preferentially demonstrate molecular ion peaks, was used to detect monoazo metal compounds of the present invention.
Generally, the reaction product obtained by the above-described metallizing reaction contains as major components a 3:2 type monoazo metal compound represented by formula I! (D 3 (Met) 2 ) and a 6:4 type monoazo metal compound represented by formula IV! (D 6 (Met) 4 ); however, FD-MS spectral analysis demonstrated that the reaction product also contains small amounts of a 2:1 type monoazo metal compound represented by formula XII! ( D 2 (Met)! - A + ) and other substances.
Because the FD (field desorption)--MS technique is an soft ionization method, fragmentation is unlikely and a simple spectrum is obtained, resulting in the preferential demonstration of molecular ion peaks Tsuchiya et al., "Current Progress of Mass Analysis" (in Japanese), Gendai Kagaku Extra Issue 15 (1989), Tokyo Kagaku Dojin; Mizuno, Kagaku to Kogyo, 64, 578, 507 (1990); Mizuno et al., Kagaku to Kogyo, 66, 569 (1992)!.
The chemical structures of the 3:2 type monoazo metal compound of the present invention, represented by formula I! (D 3 (Met) 2 ), and the 6:4 type monoazo metal compound of the present invention, represented by formula IV! (D 6 (Met) 4 ), can be respectively shown by molecular structures (i) or (ii) and (iii) or (iv) below. These molecular models, deduced from molecular weight data obtained by FD-MS spectral analysis, were shown to be possible by chemical bond analysis based on the molecular orbital theory. ##STR9##
The monoazo metal compounds of the present invention represented by formulas I! (D 3 (Met) 2 ) and IV! (D 6 (Met) 4 ) are exemplified by compounds (a) through (c) below. With respect to these example compounds, the molecular weight range was estimated in consideration of Cl isotopes. ##STR10##
The toner of the present invention for developing electrostatic images and the powdery paint of the present invention for electrostatic painting may incorporate various dyes and pigments as coloring agents. Examples of useful coloring agents include organic pigments such as Quinophthalone Yellow, Isoindolinone Yellow, Perinone Orange, Perinone Red, Perylene Maroon, Rhodamine 6G Lake, Quinacridone Red, Anthanthron Red, Rose Bengale, copper Phthalocyanine Blue, copper Phthalocyanine Green and diketopyrrolopyrrole pigments; and inorganic pigments and metal powders such as Carbon Black, Titanium White, Titanium Yellow, Ultramarine, Cobalt Blue, Red Iron Oxide, aluminum powder and bronze.
Examples of resins useful in the toner and powdery paint of the present invention include the following resins. Specifically, useful resins for toners include thermoplastic resins such as styrene resin, styrene-acrylic resin, styrene-butadiene resin, styrene-maleic acid resin, styrene-vinyl methyl ether resin, styrene-methacrylic acid ester copolymer, polyester resin and polypropylene resin; useful resins for paints include thermoplastic resins of the acryl-, polyolefin-, polyester-, polyamide- or other series, and thermosetting resins of the phenol-, epoxy-, polyester- or other series.
These resins may be used singly or in blends.
With respect to the toner of the present invention for developing electrostatic images and the powdery paint of the present invention for electrostatic painting, it is preferable that an above-described monoazo metal compound of the present invention or an above-described composition of the present invention be incorporated as a charge control agent or charge enhancer in a ratio of 0.1 to 10 parts by weight per 100 parts by weight of resin. More preferably, the content ratio of charge control agent or charge enhancer is 0.5 to 5 parts by weight per 100 parts by weight of resin.
The toner of the present invention for developing electrostatic images can, for example, be produced as follows:
After a resin and coloring agent (preferably Carbon Black) as described above, an above-described monoazo metal compound of the present invention or an above-described composition of the present invention as a charge control agent, and, if necessary, a magnetic material, a fluidizing agent, a releasing agent and other additives, are thoroughly mixed using a ball mill or another mechanical mixer, the mixture is kneaded in a molten state using a hot kneader such as a heat roll, kneader or extruder. The resulting molten mixture is cooled and solidified, followed by pulverization and particle classification by size, to yield a toner 5 to 20 μm in mean particle diameter.
Other usable methods include the method in which other starting materials are dispersed in a binder resin solution for toners and then spray dried to yield a toner, and the method in which a given set of starting materials are mixed in a monomer for toner binder resin to yield an emulsified suspension, which is then polymerized to yield a polymeric toner.
When the toner of the present invention is used as a two-component developer, development can be achieved by the two-component magnetic brush developing process or the like using the toner of the present invention in mixture with carrier powder.
Any known carrier can be used. Examples of the carrier include iron powder, nickel powder, ferrite powder and glass beads about 50 to 200 μg m in particle diameter, and such materials as coated with acrylic acid ester copolymer, styrene-acrylic acid ester copolymer, styrene-methacrylic acid ester copolymer, silicone resin, polyamide resin, ethylene fluoride resin or the like.
When the toner of the present invention is used as a one-component developer, an appropriate amount of fine powder of a ferromagnetic material such as iron powder, nickel powder or ferrite powder may be added and dispersed in preparing the toner as described above. Examples of developing processes which can be used in this case include contact development and jumping development.
The powdery paint of the present invention for electrostatic painting may be colored by, for example, the addition of a pigment, and may incorporate a filler such as Titanium White, talc, kaolin, silica, alumina, calcium carbonate, aluminum sulfate, barium sulfate, calcium sulfate, titanium oxide or calcium phosphate.
Painting with the powdery paint of the present invention for electrostatic painting can be achieved using an ordinary method of electrostatic powder painting such as the corona charging method, frictional charging method or hybrid method, and permits efficient obtainment of features of powdery paint, such as i) capability of forming a thick coating film without film defects, ii) improvement of coating film performance, and iii) absence of painting loss during painting operation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an FD-MS spectrum of the composition obtained in Example 1.
FIG. 2 is an FD-MS spectrum of the composition obtained in Example 2.
FIG. 3 is an FD-MS spectrum of the composition obtained in Example 3.
FIG. 4 is an FD-MS spectrum of the composition obtained in Example 4.
FIG. 5 is an FD-MS spectrum of the composition obtained in Example 5.
EXAMPLES
The present invention is hereinafter described in more detail by means of the following examples, which are not to be construed as limitative on the present invention. In the description given below, figures for part(s) by weight are simply referred to as part(s).
Example 1
To 620 g of ethyl cellosolve and 380 g of ethylene glycol, 110 g (0.59 mol) of chromium (III) formate was added; this mixture was stirred at 80° C. for 1 hour.
To this mixture, 415 g (1.39 mol) of monoazo compound (1) was added; after the temperature was raised to 125° C., the mixture was stirred for 4 hours.
This reaction mixture was dispersed in 4000 ml of a 3% aqueous solution of hydrochloric acid and stirred at 60° C. for 1 hour, after which this mixture was filtered; the cake filtered out was washed with warm water and dried to yield 400 g of a purple powder.
This powder was subjected to molecular weight determination by the FD-MS technique; the mass spectrum shown in FIG. 1 was obtained the abscissa indicates M/Z (mass/charge) and the ordinate indicates relative abundance (content ratio); the same applies to FIGS. 2 through 5!.
The mass spectrum of FIG. 1 identified a 3:2 type metal compound of the present invention (example monoazo metal compound (a)) M/Z, 993 (M + )!, which is the major reaction product, a 2:1 type metal compound ({ example monoazo compound (1)! 2 (Cr)} - .H + ) M/Z, 643 (M + -2)!, and unreacted example monoazo compound (1) M/Z, 298 (M + )!.
Molecular weight determination by the FD-MS technique was conducted as follows (the same applies to the Examples below).
The sample, dissolved or dispersed in DMF, was analyzed using a mass analyzer JMS-DX303HF (trade name), produced by JEOL Ltd.! to obtain a mass spectrum showing the sample's molecular weight.
Analytical conditions A: FD-MS (Field Desorption Mass Spectroscopy) technique (field leaving ionization method)--Carbon emitter used
Resolution: 1500, 35-2200 M/Z
Acceleration voltage: 2.5 kV
Ion multiplier: 1.5-2.5 kV
Emitter amperage: 0-40 mA
Cathode voltage: 5.0 kV
Example 2
82 g (0.6 mol) of salicylic acid was dissolved in 500 g of a 16% aqueous solution of sodium hydroxide; after the temperature was raised to 60° C., 470 g of a 13.4% aqueous solution of iron (III) chloride was added little by little, followed by stirring for 20 minutes to achieve dissolution.
The resulting solution was added to a solution of 150 g (0.5 mol) of example monoazo compound (1) in a 4% aqueous solution of sodium hydroxide; after the temperature was raised to 100° C., the mixture was stirred for 2 hours, after which 65.9 g of a 37% aqueous solution of iron (III) chloride was added, followed by stirring for 1.5 hours.
This reaction mixture was dispersed in 2500 ml of a 1.5% aqueous solution of hydrochloric acid and stirred at 60° C. for 10 minutes, after which the mixture was filtered; the cake filtered out was washed with 2000 ml of hot water and dried to yield 182 g of a black powder.
This powder was subjected to molecular weight determination by the FD-MS technique; the mass spectrum shown in FIG. 2 was obtained.
The mass spectrum of FIG. 2 identified a 3:2 type metal compound of the present invention (example monoazo metal compound (d)) M/Z, 999 (M + -1)!, which is the major reaction product, and a small amount of a 2:1 type metal compound ({ example monoazo compound (1)! 2 (Fe)} - .H + ) M/Z, 647 (M + -2)!.
Example 3
82 g (0.6 mol) of salicylic acid was dissolved in 500 g of a 16% aqueous solution of sodium hydroxide; after the temperature was raised to 60° C., 470 g of a 13.4% aqueous solution of iron (III) chloride was added little by little, followed by stirring for 20 minutes to achieve dissolution.
The resulting solution was added to a solution of 150 g (0.5 mol) of example monoazo compound (1) in a 4% aqueous solution of sodium hydroxide; after the temperature was raised to 100° C., the mixture was stirred for 4 hours.
This reaction mixture was dispersed in 2500 ml of a 1.5% aqueous solution of hydrochloric acid and stirred at 60° C. for 10 minutes, after which the mixture was filtered; the cake filtered out was washed with 2000 ml of hot water and dried to yield 147 g of a black powder.
This powder was subjected to molecular weight determination by the FD-MS technique; the mass spectrum shown in FIG. 3 was obtained.
The mass spectrum of FIG. 3 identified a 3:2 type metal compound of the present invention (example monoazo metal compound (d)) M/Z, 999 (M + -1)! and a 2:1 type metal compound ({ example monoazo compound (1)! 2 (Fe)} - .Na + ) M/Z, 670 (M + -1)! in an almost 1:1 ratio.
Example 4
82 g (0.6 mol) of salicylic acid was dissolved in 500 g of a 16% aqueous solution of sodium hydroxide; after the temperature was raised to 60° C., 470 g of a 13.4% aqueous solution of iron (III) chloride was added little by little, followed by stirring for 20 minutes to achieve dissolution.
The resulting solution was added to a solution of 209 g (0.5 mol) of example monoazo compound (11) in a 4% aqueous solution of sodium hydroxide; after the temperature was raised to 100° C., the mixture was stirred for 2 hours.
This reaction mixture was dispersed in 2500 ml of a 1.5% aqueous solution of hydrochloric acid and stirred at 60° C. for 10 minutes, after which the mixture was filtered; the cake filtered out was washed with 2000 ml of hot water and dried to yield 176 g of a black powder.
This powder was subjected to molecular weight determination by the FD-MS technique; the mass spectrum shown in FIG. 4 was obtained.
The mass spectrum of FIG. 4 identified a 3:2 type metal compound of the present invention (example monoazo metal compound (e)) M/Z, 1359 (M + )!, which is the major reaction product.
Example 5
To 228 g (0.76 mol) of example monoazo compound (1), 340 g of ethyl cellosolve and 220 g of ethylene glycol, a mixture of 76.0 g (0.41 mol) of chromium (III) formate and 24 g of urea was added; this mixture was stirred at 130° C. for 3 hours.
This reaction mixture was filtered while it remained hot; the filtrate was dispersed in an aqueous solution consisting of 30 g of 35% hydrochloric acid and 2000 ml of water, followed by stirring at 50° to 60° C. for about 30 minutes, after which the mixture was filtered; the cake filtered out was washed with water and dried to yield 220 g of a blackish purple powder.
81 g of the powder obtained was washed with a methanol using Soxhlet extractor and dried to yield 71 g of a blackish brown powder.
This powder was subjected to molecular weight determination by the FD-MS technique; the mass spectrum shown in FIG. 5 was obtained.
The mass spectrum of FIG. 5 identified a 6:4 type metal compound of the present invention (example monoazo metal compound (g)) M/Z, 1987 (M + )!, which is the major reaction product, and very small amounts of a 3:2 type metal compound of the present invention (example monoazo compound (a)) M/Z, 993 (M + )! and a 2:1 type metal compound of the present invention ({ example monoazo compound (1)! 2 (Cr)} - .H + ) M/Z 644 (M + -1)!.
Toner for developing electrostatic images
Next, a toner for developing electrostatic images whose charge control agent is based on a monoazo metal compound of the present invention (and also a composition of the present invention) is hereinafter described with reference to Examples A through C.
Example A
Styrene-acrylic copolymer resin HIMER SMB600 (trade name), produced by Sanyo Kasei Co., Ltd.! . . . 100 parts
Low polymer polypropylene Biscal 550P (trade name), produced by Sanyo Kasei Co., Ltd.! . . . 3 parts
Carbon Black MA-100 (trade name), produced by Mitsubishi Chemical Industries, Ltd.! . . . 6 parts
Charge control agent (composition obtained in Example 1) . . . 1 part
The above ingredients were uniformly pre-mixed using a high-speed mixer, and then kneaded in a molten state using a heat roll, cooled, and roughly milled in a vibration mill.
The obtained coarse product was finely pulverized using an air jet mill equipped with a classifier to yield a negatively chargeable toner 10 to 20 g m in particle size.
Five parts of this toner was admixed with 95 parts of an iron powder carrier TEFV 200/300 (trade name), produced by Powdertech Co., Ltd.) to yield a developer.
The developer was thoroughly stirred and the amount of charges of the developer was determined by the blowoff method using a blowoff charge analyzer TB-200 (trade name), produced by Toshiba Chemical Corporation); the amount of initial blowoff charges of the developer was found to be -29.7 μC/g. The amounts of initial blowoff charges of the developer under low-temperature low-humidity conditions and high-temperature high-humidity conditions were -29.0 μC/g and -28.8 μC/g, respectively, demonstrating very high stability; storage stability was also good.
When this developer was used for repeated cycles of actual imaging on a commercially available copying machine, high-quality images free of density reduction and fogging were obtained, with good charge stability and sustainability and no high-temperature offset phenomenon.
Example B
A toner according to the present invention and a developer were prepared and assessed in the same manner as in Example A, except that the charge control agent composition used in Example A was replaced with that obtained Example 2. The amount of initial blowoff charges of the developer was determined to be -21.3 μC/g. The amounts of initial blowoff charges of the developer under low-temperature low-humidity conditions and high-temperature high-humidity conditions were -21.5 μC/g and 31 20.0 μC/g, respectively, demonstrating very high stability; storage stability was also good. When this developer was used for repeated cycles of actual imaging in the same manner as in Example A, high-quality images free of density reduction and fogging were obtained, with good charge stability and sustainability and no high-temperature offset phenomenon, as in Example A.
Example C
Polyester resin HP-301 (trade name), produced by The Nippon Synthetic Chemical Industry, Co., Ltd.! . . . 100 parts
Low polymer polypropylene Biscal 550P (trade name), produced by Sanyo Kasei Co., Ltd.! . . . 2 parts
Carbon Black MA-100 (trade name), produced by Mitsubishi Chemical Industries, Ltd.! . . . 6 parts
Charge control agent (composition obtained in Example 5) . . . 1 part
The above ingredients were treated in the same manner as in Example A to yield a negatively chargeable toner, which was then used to prepare a developer.
When this developer was used for repeated cycles of actual imaging, high-quality images free of density reduction and fogging were obtained, with good charge stability and sustainability. The offset phenomenon was not noted.
Comparative Example 1
A toner and developer were prepared and assessed in the same manner as in Example A, except that the charge control agent used in Example A was replaced with a chromium complex compound of the following structure (Cr complex compound of the monoazo compound and t-butylsalicylic acid disclosed in Japanese Patent Unexamined Publication No. 29254/1984). The amount of charges and charge stability were problematic. When this developer was used for repeated cycles of actual imaging, image scattering, derangement, fogging and other drawbacks were noted. ##STR11##
Comparative Example 2
A toner and developer were prepared and assessed in the same manner as in Example A, except that the charge control agent used in Example A was replaced with an Mg complex compound of t-butylsalicyclic acid of the following structure (disclosed in Japanese Patent Unexamined Publication No. 163061/1987). The amount of charges and charge stability were problematic. When this developer was used for repeated cycles of actual imaging, image scattering, derangement, fogging and other drawbacks were noted; the charge control agent failed to exhibit satisfactory effect. ##STR12## Powdery paints for electrostatic painting
Next, powdery paints for electrostatic painting whose charge enhancer is based on a monoazo metal compound of the present invention (and also a composition of the present invention) are described with reference to Examples D through G.
Although painting with the powdery paint of the present invention for electrostatic painting can be achieved using an ordinary method of electrostatic painting such as the corona charging method, frictional charging method or hybrid method, electrostatic painting by the frictional charging method is primarily described here.
As shown in Table 1, 97 to 98 parts of a resin for powdery paint, 2 to 3 parts of the charge enhancer composition obtained in Example 1, 3, 4 or 5, and 0 to 5 parts of a coloring agent were uniformly pre-mixed using a ball mill, and then kneaded in a molten state using a heat roll, cooled, and roughly and finely milled to yield a powdery paint for electrostatic painting of 20 to 250 μm in particle size.
When the powdery paints for electrostatic painting thus obtained were subjected to a painting test by the tribocharge method on a steel plate using a frictional charging electrostatic powdery painting machine Tribomatic (trade name), produced by Nordson K. K.!, painted products having good appearance and no painting film defects were obtained at a paint adhesion efficiency of not less than 96%.
TABLE 1______________________________________Example Powdery paint composition Powdery paint Paint______________________________________D 97 parts of acrylic resin Negatively 99 and 3 parts of charge chargeable enhancer obtained in Example 1E 98 parts of acrylic resin Negatively 98 and 2 parts of charge chargeable enhancer obtained in Example 4F 97 parts of polyester Negatively 98 resin and 3 parts of chargeable charge enhancer obtained in Example 5G 98 parts of acrylic resin Negatively 96 and 2 parts of charge chargeable enhancer obtained in Example 3______________________________________
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Monoazo metal compound of formula I! which is excellent in charge control or charge-enhancing property, and toner for developing electrostatic images and powdery paint for electrostatic painting incorporating thereof:
D.sub.3 (Met).sub.2 I!
D is a ligand based on a monoazo compound of formula II! or III!, Met is a metal atom, and the 3 molecules of D are coordinated to the 2 atoms of Met: ##STR1## R 1 -R 10 and R 21 -R 28 are each H, halogen, nitro, alkyl or haloalkyl, aryl, aralkyl, --SO 2 N(R 11 ) 2 (R 11 is H, alkyl, aryl, aralkyl), --N(R 12 ) 2 (R 12 is H, lower alkyl, aryl, aralkyl, acyl), --CONH(R 13 ) (R 13 is H, a lower alkyl, aryl, aralkyl); 2 or more of R 1 -R 10 and/or R 21 -R 28 may bind together to form an aromatic or aliphatic ring.
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FIELD OF THE INVENTION
[0001] The present invention relates to the method and the system for a speech input, and more particular to the method and the system for a speech input of a headset device.
BACKGROUND OF THE INVENTION
[0002] The wireless electronic device has become more popular due to the property of the remote operation capacity and the getting mature techniques thereof. At present, various electronic devices with the capability of transmitting data via wireless techniques have been provided. Nevertheless, the current wireless headset device, such as the infrared-ray wireless earphone and the bluetooth wireless earphone, is used as the medium for the two-way communication of information.
[0003] In order to answer the digital trend, the user always would like to control the surrounding electronic devices directly via the wireless headset deice by means of using the wireless headset device. Nevertheless, one of the defects of the current wireless electronic device is that the input and output interface thereof is not friendly enough and the user always could not operate the wireless electronic device at his will. In order to solve the problems regarding the information communication between wireless electronic devices, lots of studies for the information communication have been made. One popular way to increase the convenience of the communication between wireless electronic devices is the friendly human input interface, such as the speech input interface, whereby the user could transmit a command directly via a speech.
[0004] In addition, since the computing ability of the current electronic device is not so powerful and the user could not give a command arbitrarily, it is desirous to provide a mechanism to increase the success rate of the speech recognition.
[0005] In order to increase the success rate of the speech recognition of the wireless electronic device and the convenience of operating the wireless electronic device, the present invention provides the new method and system for a speech input. In the present invention, a hierarchical guide mechanism is provided.
SUMMARY OF THE INVENTION
[0006] In accordance with one respect of the present invention, a method for speech input is provided. The method includes steps of: (a) establishing a hierarchical command list having a plurality of classified commands and a plurality of predetermined commands in a first device, (b) issuing a first speech command to the first device from a third device of a second device so that the first device obtains a first classified command corresponding to the first speech command, (c) determining a first command set from the plurality of predetermined commands via the first device based on the first classified command, (d) controlling the first device by the third device so as to cyclically provide each command in the first command set, (e) issuing a second speech command according to the each command in the first command set, (f) recognizing the second speech command with the first device, and (g) performing an operation corresponding to the recognized second speech command.
[0007] Preferably, the first device is a processor.
[0008] Preferably, the second device is a wireless electronic device.
[0009] Preferably, the wireless electronic device is a headset.
[0010] Preferably, the third device is a key.
[0011] Preferably, the step b) includes steps of: b1) providing the plurality of determined classified commands by the first device, and b2) issuing the first speech command after the first device provides a desired classified command.
[0012] Preferably, the step by includes steps of: b1) providing the plurality of determined classified commands by controlling the first device with the third device, and b2) issuing the first speech command after the first device provides a desired classified command.
[0013] In accordance with another respect of the present invention, a speech operating method for a wireless electronic device having a key and wirelessly communicating with a processor device is provided. The method includes steps of: a) establishing a hierarchical command list having a plurality of classified commands arranged in a plurality of levels and a plurality of predetermined commands in the processor device, b) selecting a first classified command in a level by controlling the key, c) sending a first speech command according to the first classified command, d) providing a second classified command in a sublevel by the processor device according to the first speech command, e) finding out a final classified command by repeating the steps b) to d), f) providing a command corresponding to the final classified command to the wireless electronic device from the processor device, g) sending a second speech command according to the provided command in the step of f), h) recognizing the second speech command by the processor device, and i) performing an operation corresponding to the second speech by the processor device.
[0014] Preferably, the wireless electronic device is a headset.
[0015] Preferably, the processor device is a mobile phone.
[0016] Preferably, the processor device is a personal digital assistant.
[0017] In accordance with another respect of the present invention, a speech input system is provided. The speech input system includes a main device and a wireless electronic device. The main device has a speech recognition system, a first command transmitter electrically connected with the speech recognition system, and a first command receiver electrically connected with the speech recognition system. The wireless electronic device wirelessly communicates with the main device has a second command transmitter, a second command receiver electrically connected with the second command transmitter, a key electrically connected with second command transmitter, a sound device electrically connected with the second command receiver and a speech receiver electrically connected with the second command transmitter.
[0018] Preferably, the wireless electronic device is a headset.
[0019] Preferably, the main device is a mobile phone.
[0020] Preferably, the main device is a personal digital assistant.
[0021] The foregoing and other features and advantages of the present invention will be more clearly understood through the following descriptions with reference to the drawings, wherein:
BRIEF DESCRIPTION OF THE DRAWING
[0022] FIG. 1 is a diagram showing the speech input system according to a preferred embodiment of the present invention;
[0023] FIG. 2 is a diagram showing a hierarchical command tree according to a preferred embodiment of the present invention; and
[0024] FIG. 3 is a diagram showing a hierarchical command tree according to another preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] The present invention will now be described more specifically with reference to the following embodiments. It is to be noted that the following descriptions of preferred embodiments of this invention are presented herein for purpose of illustration and description only; it is not intended to be exhaustive or to be limited to the precise form disclosed.
[0026] Please refer to FIG. 2 , which is a diagram showing the speech input system according to a preferred embodiment of the present invention. As shown in FIG. 1 , the speech input system 1 includes a main device 11 , such as a processor, a PDA or a cell phone, and a wireless electronic device 12 , such as a bluetooth earphone or other headsets. The main device 11 includes a speech recognition system 111 , a predetermined command transmitter 112 and a command receiver 113 . The wireless electronic device 12 includes a predetermined command receiver 121 , a command transmitter 122 , a key 123 , a predetermined command sound device 124 and a speech command receiver 125 . The speech recognition system 111 includes a hierarchical command tree having a plurality of classified commands, a plurality of predetermined commands and a plurality of potential speech commands.
[0027] Please refer to FIG. 2 , which is a diagram showing a hierarchical command tree according to an embodiment of the present invention. As shown in FIG. 2 , A, B and C are the classified commands, A- 1 , A- 2 , A- 3 , A- 1 - 1 , A- 1 - 2 , B- 1 , B- 2 , B- 3 , C- 1 , C- 2 , C- 2 - 1 , C- 2 - 2 , C- 2 - 3 , and C- 2 - 4 are the predetermined commands, and A′, B′,C′, A- 1 ′, A- 2 ′, A- 3 ′, A- 1 - 1 ′, A- 1 - 2 ′, B-i′, B- 2 ′, B- 3 ′, C-i′, C- 2 ′, C- 2 -l′, C- 2 - 2 ′, C- 2 - 3 ′, and C- 2 - 4 ′ are the potential speech commands.
[0028] Please refer to FIGS. 1 and 2 , during the operation of the speech input system 1 , the main device 11 would transmit the classified command A in Level 1 to the wireless electronic device 12 via the predetermined command transmitter 112 and the predetermined command receiver 121 . Then, the predetermined command sound device 124 would inform a user (not shown) with the classified command A After understanding the classified command A, the user would determine whether the classified command A is desired. If the classified command A is desired, the user could provide a speech command A′ associated with the classified command A. After the speech command receiver 125 receives the speech command A′, the received speech command A′ would be transmitted to the command receiver 113 via the command transmitter 122 . After that, the received speech command A′ would be transmitted to the speech recognition system 111 and recognized thereby. Then, the operation goes to the next level, i.e. Level 2 .
[0029] When the relevant operation goes to Level 2 , the main device 11 transmits the predetermined command A- 1 to the wireless electronic device 12 , and then the predetermined command sound device 124 would inform the user with the predetermined command A- 1 . After understanding the predetermined command A- 1 , the user would determine whether the predetermined command A- 1 is desired. If the predetermined command A- 1 is desired, the user could provide a speech command A- 1 ′ associated with the predetermined command A- 1 . After the speech command receiver 125 receives the speech command A- 1 ′, the received speech command A- 1 ′ would be transmitted to the speech recognition system 111 via the command transmitter 122 and command receiver 113 and then recognized thereby. Then, the operation will go to the next level, i.e. Level 3 .
[0030] When the relevant operation goes to Level 3 , the main device 11 transmits the predetermined command A- 1 - 1 to the wireless electronic device 12 via the predetermined command receiver 121 , and then the predetermined command sound device 124 would inform the user with the predetermined command A- 1 - 1 . After understanding the predetermined command A- 1 - 1 , the user would determine whether the predetermined command A- 1 - 1 is desired. If the predetermined command A- 1 - 1 is desired, the user could provide a speech command A- 1 - 1 ′ associated with the predetermined command A- 1 - 1 . After the speech command receiver 125 receives the speech command A- 1 - 1 ′, the received speech command A- 1 - 1 ′ would be transmitted to the speech recognition system 111 via the command transmitter 122 and command receiver 113 and then recognized thereby. After recognition, the main device 11 would carry out the action indicated by the speech command A- 1 - 1 ′.
[0031] Please refer to FIGS. 1 and 2 again. During the operation of the speech input system 1 , the main device 11 would transmit the classified command A in Level 1 to the wireless electronic device 12 via the predetermined command transmitter 112 . Then, the predetermined command sound device 124 would inform a user (not shown) with the classified command A. After understanding the classified command A, the user would determine whether the classified command A is desired. If the classified command A is undesired, the user could press the key 123 to provide a first information (not shown) to the main device 11 via the command transmitter 122 and the command receiver 113 . Then the main device 11 would provide the classified command B to the wireless electronic device 12 . Then, the predetermined command sound device 124 would inform the user with the classified command B. After understanding the classified command B, the user would determine whether the classified command B is desired. If the classified command B is undesired, the user could press the key 123 again to provide a second information (not shown) to the main device 11 via the command transmitter 122 and the command receiver 113 . Then the main device 11 would provide the classified command C to the wireless electronic device 12 . After understanding the classified command C, the user would determine whether the classified command C is desired. If the classified command C is desired, the user could provide a speech command C′ associated with the classified command C. After the speech command receiver 125 receives the speech command C′, the received speech command C′ would be transmitted to the command receiver 113 via the command transmitter 122 . After that, the received speech command C′ would be transmitted to the speech recognition system 111 and recognized thereby. Then, the operation goes to the next level, i.e. Level 2 .
[0032] When the relevant operation goes to Level 2 , the main device 11 transmits the predetermined command C- 1 to the wireless electronic device 12 , and then the predetermined command sound device 124 would inform the user with the predetermined command C- 1 . After understanding the predetermined command C- 1 , the user would determine whether the predetermined command C- 1 is desired. If the predetermined command C- 1 is undesired, the user could press the key 123 to provide a third information (not shown) to the main device 11 via the command transmitter 122 and the command receiver 113 . Then the main device 11 would provide the predetermined command C- 2 to the wireless electronic device 12 . After understanding the predetermined command C- 2 , the user would determine whether the predetermined command C- 2 is desired. If the predetermined command C- 2 is desired, the user could provide a speech command C- 2 ′ associated with the classified command C- 2 . After the speech command receiver 125 receives the speech command C- 2 ′, the received speech command C- 2 ′ would be transmitted to the command receiver 113 via the command transmitter 122 . After that, the received speech command C- 2 ′ would be transmitted to the speech recognition system 111 and recognized thereby. Then, the operation goes to the next level, i.e. Level 3 . Similar to the above illustrations, the operation goes to the communications about the predetermined commands C- 2 - 1 , C- 2 - 2 , C- 2 - 3 and C- 2 - 4 . As above, the user could find out the desired predetermined command by the hierarchical communication mechanism.
[0033] Please refer to FIGS. 1 and 2 again. It is to be noted that when the operation in within Level 1 , the user could only select the classified commands A, B or C via the key 123 . After the desired classified command is found, the operation goes to Level 2 . Then, the main device 11 determines the next predetermined commands according to the relevant selected parent nodes (i.e. the classified commands A, B or C). For example, if the classified command A is desired and selected, the predetermined commands provided in Level 2 would be A- 1 , A- 2 and A- 3 rather than B- 1 , B- 2 , B- 3 , C- 1 and C- 2 . As above, after the hierarchical selection and communication, the user would find out the desired speech command by the suggestion of the speech input system 1 .
[0034] Please refer to FIG. 3 , which shows a hierarchical tree according to another embodiment of the present invention.
[0035] Please refer to FIGS. 1 and 3 . During the operation, the user could select the desired classified command from the predetermined commands, “channel and program”, “channel”, “classification and program” and “classification” via the key 123 . If the user selects the classified command “classification” and then provides a speech command “movie”, the speech recognition system 11 would recognize the speech command. After the speech recognition system 11 recognizes the speech command “movie”, the main device 11 would prompt the predetermined commands, “actor name” and “publisher”, in Level 2 and then the user could select the desired predetermined classified command via the key 123 . If the user provides a speech command “Dream Work” while the predetermined command “publisher” is selected, the speech recognition system 11 would recognize the speech command. After the speech recognition system 11 recognizes the speech command “Dream Works”, the main device 11 would prompt the predetermined commands, “Shrek 1”, “Shrek 2”, “Shark Tale” and “Madagascar”, in Level 3 and then the user could select the desired predetermined classified command via the key 123 again. If the user provides the speech command “Play” while the predetermined command “Shrek 1” is selected, and then the main device 11 would send a signal to the playing device(such as DVD player) to play the movie immediately.
[0036] As mentioned above, it is believed that one skilled in the art should understand that the present invention provides the method and system relating to the provision of the speech suggestion and the control via a key for a command input. In addition, with the provided hierarchical guide mechanism and the key, it is possible for the user to provide a proper speech command to increase the recognition rate of the relevant device and the correctness of the action of the relevant devices. As mentioned above, the present invention indeed has novelty, progressiveness and industry application.
[0037] While the invention has been described in terms of what are presently considered to be the most practical and preferred embodiments, it is to be understood that the invention need not be limited to the disclosed embodiment. On the contrary, it is intended to cover various modifications and similar arrangements included within the spirit and scope of the appended claims which are to be accorded with the broadest interpretation so as to encompass all such modifications and similar structures. Therefore, the above description and illustration should not be taken as limiting the scope of the present invention which is defined by the appended claims.
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A method for a speech input is provided. The method includes steps of: (a) establishing a hierarchical command list having a plurality of classified commands and a plurality of predetermined commands in a first device, (b) issuing a first speech command to the first device from a third device of a second device so that the first device obtains a first classified command corresponding to the first speech command, (c) determining a first command set from the plurality of predetermined commands via the first device based on the first classified command, (d) controlling the first device by the third device so as to cyclically provide each command in the first command set, (e) issuing a second speech command according to the each command in the first command set, (f) recognizing the second speech command with the first device, and (g) performing an operation corresponding to the recognized second speech command.
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BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] This disclosure relates to power converters. In particular, this disclosure relates to a step down (buck) power converter with inductor based switching, suitable for use with a memory device (e.g., a flash memory device) or other device.
[0003] 2. Related Art
[0004] Continual development and rapid improvement in semiconductor manufacturing techniques have led to extremely high density memory devices. The memory devices are available in a wide range of types, speeds, and functionality. Memory devices often take the forms, as examples, of flash memory cards and flash memory drives. Today, capacities for memory devices have reached 64 gigabytes or more for portable memory devices such as Universal Serial Bus (USB) flash drives, and one terabyte or more for solid state disk drives. Memory devices form a critical part of the data storage subsystem for digital cameras, digital media players, home computers, and an entire range of other host devices.
[0005] One important characteristic of a memory device is its power consumption. In an age when many host devices are powered by limited capacity batteries, every fraction of a watt in power saving translates into extended battery life and extended functionality between recharges for the host device. While the memory device is in operation, a power converter provides the power supply to the memory device. A buck power converter typically has much higher efficiency than other types of power converters. This is one reason that buck converters are frequently preferred over linear regulators and charge pump regulators.
[0006] However, memory devices present significant technical challenges to the use of a buck regulator. As one example, the form factor of the circuit board in a memory device is often very small. As a result, it is difficult to find space for large off-chip components like the inductor or capacitor used in a buck regulator. Furthermore, the components add extra cost to the memory device, and cost margins for memory devices are already very small.
[0007] The sizes of the inductor and capacitor are inversely proportional to the switching frequency of the control loop in the buck regulator. According, in the past, very high switching frequencies on the order of tens or hundreds of MHz or higher were used. Unfortunately, high switching frequencies increase design complexity and cost, while reducing the overall power efficiency. Moreover, the bandwidth of the components of a buck regulator is generally preferred to be significantly higher (e.g., 10 times or higher) than the switching frequency. This is often a difficult condition to meet, and commonly imposes significant restrictions on the maximum possible switching frequency.
[0008] One technique for addressing the technical challenges associated with buck converters is to use a multiphase approach with multiple control loops. Each phase requires its own distinct inductor and switching power transistor pairs. The control loops are driven 180 degrees out of phase. Separate pulse width modulated (PWM) signals drive the distinct power transistor pairs. In other words, the conventional multiphase approach requires multiple inductors equal in number to the number of phases. The convention approach also requires multiple power transistor pairs. As noted above, it is difficult and financially prohibitive to provide these extra components, particularly in a small, inexpensive memory device.
SUMMARY
[0009] A buck power converter creates a desired output voltage from a greater input voltage, without requiring multiple inductors or capacitors. The buck power converter has a higher efficiency than linear regulators or charge pumps. The buck power converter uses techniques that reduce the sizes of the inductor and capacitor so that they can be integrated on-chip or in-package or on board.
[0010] A signal converter in the buck power converter determines the duty cycle of a switching control signal. The signal converter outputs a modified (multiphase) switching control signal that includes multiple separated on-periods that taken together approximate the duty cycle of the switching control signal while maintaining the same control loop frequency. The multiphase switching signal drives the power switching circuit to provide current to the inductor and capacitor during each of the multiple separated on-periods. The output voltage ripple decreases by a factor of the number of phases in the modified switching signal. In this way, when the ripple amplitude is kept same, the sizes of the passive components may be reduced by the factor of the number of phases in the modified switching control signal.
[0011] Other features and advantages of the inventions will become apparent upon examination of the following figures, detailed description, and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The system may be better understood with reference to the following drawings and description. In the figures, like reference numerals designate corresponding parts throughout the different views.
[0013] FIG. 1 illustrates a buck power converter.
[0014] FIG. 2 shows a power switching circuit.
[0015] FIG. 3 shows a power switching circuit.
[0016] FIG. 4 shows a signal diagram including a modified (multiphase) switching signal.
[0017] FIG. 5 shows a signal diagram including a modified (multiphase) switching signal.
[0018] FIG. 6 shows a signal diagram including a modified (multiphase) switching signal.
[0019] FIG. 7 shows a signal diagram including a modified (multiphase) switching signal.
[0020] FIG. 8 shows one example of logic for determining the duration of two phases in a modified switching signal.
[0021] FIG. 9 shows a flow diagram of logic for generating a specific nominal output voltage V o .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] The discussion below makes reference to host devices and memory devices. A host device may be a wired or wireless device, may be portable or relatively stationary, and may run from DC (e.g., battery power), AC power, or another power source. A host device may be a consumer electronic device such as a personal computer, a mobile phone handset, a game device, a personal digital assistant (PDA), an email/text messaging device, a digital camera, a digital media/content player, a GPS navigation device, a satellite signal (e.g., television signal) receiver, or cable signal (e.g., television signal) receiver. In some cases, a host device accepts or interfaces to a memory device that includes the power converter. Examples of memory devices include memory cards, flash drives, and solid state disk drives. For example, a music/video player may accept a memory card that incorporates the power converter described below, or a personal computer may interface to a solid state disk drive that includes the power converter below. The power converter may be used in other devices, including in the host device itself.
[0023] FIG. 1 illustrates a step-down (buck) switching power converter 100 (“power converter 100 ”). The power converter 100 includes a control unit 102 , a signal converter 104 in communication with the control unit 102 , and a switching circuit 106 driven by the signal converter 104 . The power switching circuit 106 provides current to an inductor L and a capacitor C as described in more detail below. The power converter 100 provides power to a load (represented in FIG. 1 having a certain load resistance R L ) at a specific nominal output voltage V o .
[0024] The power converter 100 produces V o from a reference input voltage V in provided on the voltage reference input 108 . To do so, the control unit 102 generates a switching control signal (e.g., a Pulse Width Modulated (PWM) signal) on the switching control signal output 110 . The control unit 102 , consistent with buck converter design principles, sets the duty cycle of the switching control signal according to the desired reduction in V in needed to obtain V o . As one example, assuming V in =3.0V and V o =1.2V, then the duty cycle, D, that the control unit 102 implements is approximately 0.4. In addition, the control unit 102 may adjust the duty cycle of the switching control signal based on a feedback voltage V fb obtained, for example, from V o by the voltage divider 112 . The control unit 102 adjusts the switching control signal based on a comparison of the feedback voltage on the feedback input 114 to a reference voltage V ref provided on the reference input 116 . A control clock signal CLK 1 , provided on the control clock input 118 , provides a reference clock for the control unit 102 .
[0025] However, rather than directly drive a power switching circuit with the PWM signal as in existing buck converters, the PWM signal is first processed by the signal converter 104 . The signal converter 104 implements a multiphase conversion that produces a modified switching signal, MPhase, on the modified switching signal output 120 . As will be explained in more detail below, the signal converter 104 accepts a conversion clock signal CLK 2 on the conversion clock signal input 122 . The conversion clock signal is faster than the reference clock (e.g., by a factor of 10, although other factors may be implemented). The signal converter 104 may generate the modified switching signal based on the conversion clock signal as described in more detail below.
[0026] In summary, the power converter 100 provides the output voltage V o by generating a modified switching signal that includes multiple separated on-periods that taken together approximate the duty cycle, D. To that end, the control unit 102 outputs the switching control signal characterized by a particular duty cycle (e.g., 0.4). The signal converter 104 receives the switching control signal and determines the duty cycle. The signal converter 104 also outputs a modified switching signal that includes the multiple separated on-periods that taken together approximate the duty cycle. The modified switching signal drives the power switching circuit 106 . The inductor L and the load capacitor C are connected to the power switching circuit. The power switching circuit 106 provides current to the inductor L during each of the multiple separated on-periods, and the capacitor C charges through the inductor L.
[0027] The switching control signal may be a single phase switching signal intended to directly drive a power switching circuit, such as the power switching circuit 106 . However, the signal converter 104 instead drives the power switching circuit with the modified switching signal. As shown in FIG. 2 , the power switching circuit 106 may include a complementary transistor pair 202 that provides current to the inductor during each of the multiple separated on-periods. As another example, FIG. 3 shows that the power switching circuit 106 may include a transistor 302 and diode 304 in a configuration that provides the current to the inductor.
[0028] In one implementation, the signal converter 104 determines the duty cycle of the switching control signal as a clock count of the conversion clock signal. For example, the signal converter 104 may determine (e.g., using a counter) that the duty cycle causes the switching control signal to be asserted for a duration of approximately 4 conversion clocks out of every 10 conversion clocks. The signal converter 104 may then create the multiple separated on-periods in the modified switching signal to extend for, in sum, the clock count. The modified switching signal may include the multiple separated on-periods in the same or different period as the switching control signal. In other words, the signal converter 104 may delay the output of the modified switching signal, e.g., by one or more periods of the switching control signal.
[0029] The duty cycles determines an active period and an inactive period of the switching control signal. In one implementation, the signal converter 104 generates the multiple separated on-periods of the modified switching signal to include one or more evenly or unevenly separated on-periods during the active period, and one or more evenly or unevenly spaced separated on-periods during the inactive period. The on-periods during the active period and inactive period taken together approximate the duty cycle. In general, the on-periods may be generated during either or both of the active and inactive periods.
[0030] FIG. 4 shows a signal diagram including a modified switching signal. In particular, FIG. 4 shows the control clock 402 , conversion clock 404 , and a switching control signal 406 . In addition, FIG. 4 shows the inductor current 408 assuming the power switching circuit 106 were directly driven by the switching control signal 406 , the modified switching signal 410 , and the multiphase inductor current 412 that results from the modified switching signal 410 driving the power switching circuit 106 .
[0031] The control clock 402 has a period, T. Similarly, the conversion clock 404 has a period that is typically less than T, e.g., T/10. Thus the conversion clock 404 is faster than the control clock 402 by a preselected factor (e.g., 10). The preselected factor may vary widely, and may be chosen due to the availability of various clocks in the device in which the power converter 100 is implemented, may be chosen to keep operation of the power converter 100 within the bandwidth limitations of the circuitry (e.g., a feedback error amplifier and control loop) in the control unit 102 , may be chosen to keep the amount of ripple current in the inductor to less than a specific amount, or may be chosen based on other factors or combinations of factors. As one example, the control clock 402 may have a frequency in the range of approximately 1 MHz to approximately 4 MHz, and the conversion clock 404 may have a frequency in the range of approximately 5 MHz to approximately 40 MHz. Other frequencies may be employed depending on the implementation.
[0032] In the example shown in FIG. 4 , the switching control signal 406 has a duty cycle of approximately 0.4. The duty cycle establishes, in the switching control signal 406 , an active period 414 and an inactive period 416 . The active period 414 extends for approximately 4 conversion clocks, while the inactive period extends for approximately 6 conversion clocks.
[0033] If the switching control signal 406 were used to drive the power switching circuit 106 , a relatively large inductor ripple current 408 would result. The inductor current increases during the active period 414 as current flows into the inductor, and decreases during the inactive period 416 as current is no longer provided to the inductor. The amount of ripple in the inductor current 408 is illustrated in FIG. 4 as ΔI (PWM) 418 .
[0034] The signal converter 104 produces the modified switching signal 410 , which results in reduced inductor ripple current. Specifically, FIG. 4 shows that the modified switching signal 410 includes multiple separated on-periods 420 and 422 . Each of the on-periods 420 and 422 extend for approximately two conversion clocks, and each may be considered a separate phase, though in the same modified switching signal 410 . Taken together, the on-periods approximate the duty cycle of the switching control signal 406 of approximately four conversion clocks.
[0035] The modified switching signal 410 drives the power switching circuit 106 . As a result, the multiphase inductor current 412 evidences reduced ripple. In particular, the power converter 100 provides current to the inductor for approximately the same amount of time overall, but in multiple separated shorter durations. The reduced amount of ripple in the multiphase inductor current 412 is illustrated in FIG. 4 as ΔI (MPhase) 424 . Accordingly, the output voltage ripple also decreases, e.g., by a factor of the number of phases in the modified switching signal. One beneficial result is that the sizes of the passive components may be reduced commensurate with the number of phases in the modified switching signal, while adhering to the same ripple current and voltage design requirements for the power converter 100 . In other words, the decrease in ripple current and voltage resulting from the multi-phase implementation permits a change to smaller passive components, which in turn causes a counterbalancing increase in the ripple current and voltage while still meeting the design specification parameters.
[0036] FIG. 4 shows that there is a delay in the output of the modified switching signal 410 . In particular, the modified switching signal 410 lags one period behind the switching control signal 406 . The signal converter 104 may instead output the modified switching signal 410 in the same period as the switching control signal 406 , or may delay for additional periods. Whether or not there is a delay, may depend on the implementation of the signal converter 104 . For example, the counter in the signal converter 104 may analyze the switching control signal 406 over its first period to determine the number of conversion clocks during which the switching control signal 406 is active, and thus determine the duty cycle of the switching control signal 406 . Once the duty cycle is known, the signal converter 104 may then in subsequent periods output the multiple separated on-periods in the modified switching signal 410 to extend, in sum, over the duty cycle in terms of the conversion clock or other time reference.
[0037] FIG. 5 continues the example started in FIG. 4 . In particular, FIG. 5 shows the inductor voltage signal 502 that results from the inductor current 408 (i.e., from the switching control signal 406 , without using the modified switching signal). The amount of voltage ripple caused by the inductor current 408 is illustrated in FIG. 5 as ΔV (PWM) 504 . FIG. 5 also shows the inductor voltage signal 506 that results from the inductor current 412 (i.e., from using the modified switching signal 410 to drive the power switching circuit 106 ). The amount of voltage ripple caused by the inductor current 412 is illustrated in FIG. 5 as ΔV (MPhase) 508 and is reduced by a factor of the number of phases in the modified switching signal 410 .
[0038] FIG. 6 illustrates an alternative in which the modified switching signal 602 includes the four on-periods 604 , 606 , 608 , and 610 that taken together approximate the duty cycle of the switching control signal 406 . In effect, the modified switching signal 602 includes four phases in the same signal for driving the power switching circuit 106 .
[0039] Separating the duty cycle into four distinct on-periods results in the inductor current 612 . Specifically, the modified switching signal 602 provides current to the inductor for approximately the same period of time as the switching control signal 406 , but spread over four separated times. The resulting multiphase inductor current 612 evidences correspondingly reduced ripple because the limited on-times prevent the inductor current from building to levels that would have ordinarily been reached if the switching control signal 406 were used. The amount of ripple in the multiphase inductor current 612 is illustrated in FIG. 6 as ΔI (MPhase) 614 . A corresponding reduction in the multiphase inductor voltage 616 is illustrated in FIG. 6 as ΔV (MPhase) 618 .
[0040] FIG. 7 shows an example in which the modified switching signal 702 is separated into eight on-times labeled A through H. In total, the on-times approximate the total on-time resulting from the duty cycle in the switching control signal 406 . FIG. 7 shows the corresponding reduction in the multiphase inductor current 704 .
[0041] The example in FIG. 7 illustrates that signal converter 104 may begin to output on-times (e.g., the on-time labeled A) in the modified switching signal 702 as soon as it detects that the switching control signal 406 is asserted. The signal converter 104 may count the duration of the switching control signal 406 (e.g., in terms of the number of conversion clocks). In the meantime, the signal converter 104 continues to output additional on-times. Each on-time may have a specific duration (e.g., half of one conversion clock cycle).
[0042] The switching control signal 406 may count the number of on-times that it has output, and when the switching control signal is de-asserted, continue to output on-times until the duty cycle of the switching control signal 406 is approximated by the total number of on-times (and, e.g., in terms of the conversion clock 404 ). Thus, in FIG. 7 , the signal converter 104 continues to provide on-time E, F, G, and H. The spacing between on-time pulses may be even or uneven. If the spacing is kept generally even, then extra ripple can be avoided because there will not be extended periods of time when no current is being supplied to the inductor. In FIG. 7 , the signal converter 104 outputs evenly spaced pulses while the switching control signal 406 is asserted (as the signal converter 104 determines the duty cycle), and also outputs evenly spaced pulses while the signal converter 104 outputs the remaining pulses to cover the total on-time for the duty cycle of the switching control signal 406 .
[0043] In one implementation, the counter logic in the signal converter 104 may perform the following processing: 1) when the switching control signal 406 is asserted, the signal converter 104 asserts the modified switching signal 702 during the on-period of the conversion clock, and de-asserts the modified switching signal 702 during the off-period of the conversion clock; 2) the signal converter 104 counts the number, N, of off-periods of the modified switching signal 702 ; 3) then, when the switching control signal 406 is de-asserted, the signal converter 104 asserts, in an evenly distributed manner, the modified switching signal 702 N times during the de-asserted time of the switching control signal 406 .
[0044] Note that the improvements to the inductor sizing may permit additional implementation options for the inductor. For example, the inductor L may be implemented as a board or package trace inductor (e.g., by using a circuit board trace to form the inductor). Alternatively, the inductor may be integrated on-chip or in-package. For example, the power converter 100 may provide the power supply for a flash memory device and may be integrated into the same package or chip as the flash memory device.
[0045] FIG. 8 shows one example of logic 800 for determining the duration of two phases in the modified switching signal (e.g., the modified switching signal 410 ). A counter 802 determines the duty cycle of the switching control signal by counting, in terms of the number of conversion clocks, the duration the asserted portion of the switching control signal. In the example shown in FIG. 8 , the clock count is five (5). To determine the duration of on-times for the modified switching signal in two phases, the shift down register shifts the count right one place to divide by two (and drop the remainder). The result is two (2) conversion clock counts for the duration of one of the on-times. In addition, the subtractor 806 subtracts the result of the shift register from the clock count to obtain three (3), the duration for the second on-time in the modified switching signal.
[0046] FIG. 9 shows a flow diagram of logic 900 for generating a specific nominal output voltage V o . The controller 100 receives a switching control signal characterized by a duty cycle, D ( 902 ) and determines the duty cycle, D ( 904 ). The switching control signal may be a single phase switching signal, for example, that would ordinarily drive a power switching circuit to provide current to an inductor and capacitor.
[0047] The controller 100 will output a modified switching signal that includes a predetermined number of phases ( 906 ). As examples, the modified switching signal may include 2, 4, or more phases. For each phase, the signal converter 104 will generate an on-time of a specific duration. In other words, the signal converter 104 outputs multiple separated on-periods in modified switching signal. The multiple separated on-periods, taken together, approximate the duty cycle D.
[0048] The power converter 100 drives a power switching circuit 106 with the modified switching signal. As a result, the power converter 100 provides current to an inductor and capacitor during each of the multiple separated on-periods. A desired output voltage V o results.
[0049] As noted above, a control clock signal may be provided to the control unit 102 for generating the switching control signal. Also, a conversion clock signal that is faster than the control clock signal may be provided to the signal converter 104 for generating the modified switching signal. The duty cycle may be determined as a clock count of the conversion clock signal, and the multiple separated on-periods may be created to match the clock count.
[0050] The power converter 100 may output all or part of the modified switching control signal in the same period or different period (e.g., delayed by one period or more) as the switching control signal. In some implementations, the duty cycles determines an active period and an inactive period of the switching control signal. Outputting the modified switching signal may then include outputting evenly or unevenly spaced separated on-periods during the active period, and outputting evenly or unevenly spaced separated on-periods during the inactive period. The on-periods during the active period and inactive period taken together approximate the duty cycle.
[0051] The design parameters for any particular implementation may vary widely. The design parameters include the inductor, L, and capacitor, C, values, the desired output voltage, the reference input voltage, the source clock frequency, the conversion clock frequency, and other parameters. One specific implementation example is: L=100 nH, C=100 nF, reference clock=1 MHz, conversion clock=50 MHz, reference input voltage=3.3V, and an output voltage programmable from 0.95V to 1.3V.
[0052] The methods, control unit 102 , signal converter 104 , switching circuit 106 , and other logic described above may be implemented in many different ways in many different combinations of hardware, software or both hardware and software. For example, all or parts of the power converter 100 may be circuitry in a controller, a microprocessor, or an application specific integrated circuit (ASIC), or may be implemented with discrete logic or components, or a combination of other types of circuitry. Parts of the logic (e.g., counting logic) may be implemented as instructions for execution by a processor, controller, or other processing device and may be stored in a machine-readable or computer-readable medium such as a compact disc read only memory (CDROM), magnetic or optical disk, flash memory, random access memory (RAM) or read only memory (ROM), erasable programmable read only memory (EPROM) or other machine-readable medium. The instructions may be included in firmware that a controller executes. For example, the firmware may be operational firmware for a memory device. The controller may execute the instructions to generate an operating voltage V o for any desired part of the memory device.
[0053] While various embodiments of the invention have been described, it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible within the scope of the invention. Accordingly, the invention is not to be restricted except in light of the attached claims and their equivalents.
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A buck power converter creates a desired output voltage from a greater input voltage with higher efficiency than linear regulators or charge pumps. For compact-size and cost sensitive products, the use of the buck power converter is hindered mainly because of lack of physical space and increases in the cost of the passive components like the inductor and capacitor. Techniques are presented to reduce the sizes of the passive components so that they can be integrated on-chip or in-package or on board. A signal converter in the buck power converter determines the duty cycle of a switching control signal. The switching control signal would ordinarily have driven a power switching circuit that provides current to the inductor in the buck power converter. The signal converter outputs a modified (multiphase) switching control signal that includes multiple separated on-periods that taken together approximate the duty cycle of the switching control signal while maintaining the same control loop frequency. The multiphase switching signal drives the power switching circuit to provide current to the inductor during each of the multiple separated on-periods so that the output voltage ripple decreases by a factor of the number of phases in the modified switching signal. In this way, if the ripple amplitude is kept same, the sizes of the passive components can be reduced by the factor of the number of phases in the modified switching control signal.
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FIELD OF THE INVENTION
The invention relates to a liquid-air cooling system that includes at least one fan device comprising at least one variable-speed fan motor that powers a fan impeller to generate cooling capacity for a fluid of a cooling cycle. To control the speed of the fan motor by an automatic control system, at least one actual default value that originates from a machine unit connected to the liquid-air cooling system, is compared to a desired default value. The cooling capacity of the liquid-air cooling system is then adjusted as a function of the current output temperature values of the respective machine unit.
BACKGROUND OF THE INVENTION
EP 0 968 371 81 discloses and describes a fluid cooling device comprising a motor that powers a fan impeller and a fluid pump. The fluid pump takes fluid from an oil reservoir and conveys it into a hydraulic operating cycle. In the hydraulic operating cycle, the fluid (hydraulic medium) is heated and routed to a heat exchanger. From the heat exchanger, the cooled fluid is recirculated to the oil reservoir. The oil reservoir of the fluid cooling system is configured in the shape of a basin with particularly high-reaching basin edges that are suitable to form a housing part for receiving the fan impeller and an air-routing chute for a heat exchanger of the fluid cooling device. With the fluid cooling device, an oil reservoir can be provided in an especially compact assembly for storing and circulating large fluid volumes.
A control system and a method for controlling the speed of a plurality of fans for cooling a plurality of flow media of a machine unit are disclosed in DE 100 62 534 A1. The speed of each of the plurality of fans is controlled specifically according to an individual heat dissipation requirement of heat transfer cores. For one temperature sensor, respectively, of each of the plurality of flow media, current temperatures are monitored. Each sensor can be operated to generate a signal that displays the temperature of the respective flow medium, while transferring the signal to an electronic control device to control the respectively singular speed of each of the fans.
Using the previously described solution, temperature-control, especially cooling, tasks for a fluid of a hydraulic circuit can be basically implemented. However, particularly the temperature of the fluid that has passed through the fan device is, seen in absolute terms, dependent on the respective and varying ambient temperature of the hydraulic power pack. The output temperature of the fluid therefore fluctuates in the known hydraulic power packs and fluid cooling devices after it passes through the fan device.
SUMMARY OF THE INVENTION
An object of the present invention to provide an improved liquid-air cooling system having a fan device with a cooling capacity that takes into account the ambient temperature of the liquid-air cooling system and that is able to permanently implement an exact desired temperature of the fluid.
This object is basically achieved by a liquid-air cooling system that includes a fan device with a fan impeller powered by a variable-speed fan motor. The system basically allows for the implementation of cooling capacity for a fluid in a cooling cycle taking into account an actual default value—such as a temperature value—that originates from a machine unit that can be connected via the fluid cycle to a liquid-air cooling system. According to the invention, the liquid-air cooling system also includes the possibility of taking into account a desired default value, The desired default value is then compared to the actual default value such that the cooling capacity of the fan device is adjusted as a function of the actual output values of the machine unit that is supplied with fluid.
An automatic control system handles a corresponding desired/actual comparison and speed control of the fan motor. The actual default value and the desired default values therein can be represented by a temperature value. The actual default value and the desired default value can also be described by suitable other characteristic values that relate to a current operating point of the machine unit and a current actual temperature value that reflects the current operating conditions with regard to the liquid-air cooling system.
In an especially preferred embodiment of the liquid-air cooling system, and particularly using a memory and as a processor of the automatic control system that adjust the speed of the fan impeller, an air temperature is provided, for example as a desired default value, on the air supply side of the fan device. A desired default value is either a temperature of the ambient air of the hydraulic power pack or a temperature of the machine unit or of a component of the machine unit that receives a fluid flow-through for the purpose of temperature control.
Ambient air is provided as a cooling medium to increase the energy efficiency of the liquid-air cooling system. Advantageously, the speed of the fan motor is controlled in such a manner that the fluid temperature of the coolant is maintained at a value that is lowered, for example, by 5° Kelvin or more in comparison to a desired temperature that represents the desired default temperature. To be able to implement a cost-effective liquid-air cooling system, advantageously, a variable-speed motor is selected as the fan motor. For a fan motor control, a corresponding automatic control system is advantageously used in connection with a machine unit or, when bus systems are used, for the transmission of the desired default value as well as the actual default value, or, in the sense of a field bus system, for networking a plurality of machine units. A PID controller therein controls the speed of the fan motor. PID control systems are known to the person skilled in the art and are commonly used for controlling the operation of mechanical drives or other mechanical equipment accessories of machine units. The invention comprises using any type of PID control. The output quantity of the PID control is limited to the maximum allowable speed of the fan motor and/or the fan impeller.
In an especially preferred embodiment, the liquid-air cooling system is combined onto a compact unit with a minimized required assembly space comprising a fluid tank, a motor for powering a fluid pump, the fluid pump itself and the fan motor plus the fan impeller and any associated cooling apparatus as well as a cooler housing. Especially preferably, the motor for powering the fluid pump is mounted directly on the fluid tank.
For expediency, the geometric dimensions of the aforementioned components of the liquid-air cooling system are selected in such a manner that the fan device and the motor for powering the fluid pump essentially do not extend beyond a base area of the fluid tank.
The fluid can be, for example, transmission oil or hydraulic oil, or also a mixture of water and glycol.
With the liquid-air cooling system, very exact temperature-control tasks can be carried out on a machine tool, transmission, extruder, motor, frequency converter or on other types of machine units. Using a minimum of energy, a permanent, relative to temperature fluctuations or a temperature-controlled machine unit, exact operation of a corresponding machine unit can be achieved. Using the liquid-air cooling system, a bed of a machine unit or a singular machine component, such as a spindle of the machine unit, can be supplied with fluid, particularly a temperature-control fluid.
Other objects, advantages and salient features of the present invention will become apparent from the following detailed description, which, taken in conjunction with the annexed drawings, discloses a preferred embodiment of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring to the drawings that form a part of this disclosure and that are not drawn to scale:
FIG. 1 is a perspective view of a liquid-air cooling system according to an exemplary embodiment of the invention;
FIG. 2 is a top plan view of the liquid-air cooling system of FIG. 1 ;
FIG. 3 is a schematic circuit diagram of the liquid-air cooling system of FIG. 1 ;
FIG. 4 a is a graph of an example of the heat output from a machine unit that is supplied to the liquid-air cooling system;
FIG. 4 b is a superimposed curve diagram showing the developments over time of the temperature of the fluid before entering in the machine unit, the temperature of the fluid downstream of the pump outlet, the fluid volume flow V, and the air ambient temperature of the hydraulic power pack;
FIG. 4 c is a superimposed curve diagram showing the developments over time of the motor current of the fan motor, measured in Amperes, and the provided motor power of the fan motor, measured in kilowatts; and
FIG. 4 d is a graph showing the development over time of the speed of the fan motor.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a perspective view and partially exploded diagram of a liquid-air cooling system 1 that supplies a machine unit 9 and/or a component 11 of a machine unit 9 , shown schematically, with a fluid 5 , which fluid is envisioned as a temperature-control fluid. Associated with the liquid-air cooling system 1 is a fan device 2 that includes a variable-speed fan motor 3 , embodied as an electric motor 12 , that powers a fan impeller 4 with individual fan vanes in the manner of an axial fan. The fan impeller 4 is partially received by a fan impeller housing 22 and protective grate 17 . The fan impeller housing 22 can be made of plastic or sheet metal parts. As also seen in FIG. 2 in a top view of the liquid-air cooling system of FIG. 1 , a protective grate 18 is provided in the rear section of the fan impeller 4 for safety reasons. On the opposite side of the fan impeller 4 , a heat exchanger 19 in the form of a cellular radiator is disposed in relation to the protective grate 18 . The heat exchanger 19 extends across the totality of the projection area swept by the fan impeller 4 .
As shown in FIG. 1 , the fan impeller 4 sucks ambient air from right to left through the ribs of the cellular radiator and toward the fan motor 3 . In principle, the presently shown fan device 2 can also be designed and operated with the cooling air in the opposite direction of flow. The fan impeller housing 22 is designed as a box mounted vertically on a fluid tank 13 . The fluid tank 13 is essentially formed as a block-shaped component. The cross-section of the fluid tank 13 has an L-shape, as shown in FIG. 1 , such that an assembly base 20 for a motor 15 is elevated above the remainder of the cross-section of the fluid tank 13 and is formed for a motor 15 of a fluid pump 14 located inside the fluid tank 13 . The distributor rail 7 is disposed on the fan impeller housing 22 . A sensor 28 for detecting the actual temperature Ta is disposed in the fluid connection of the heat exchanger 19 between the cellular radiator 19 and the fluid tank 13 . The control system 24 is disposed on the motor 3 . The sensor for detecting the desired temperature 10 is disposed in the direction of flow upstream of the cellular radiator 19 and protected against direct air flow. The total fan device 2 and the motor 15 for powering the fluid pump 14 extend only negligibly beyond a base area 16 of the fluid tank 13 . The desired temperature can additionally or alternately also be measured directly on the machine unit that is in operation by a corresponding sensor.
A motor control unit 24 is mounted directly on the top side of the fan motor 3 , or the outside area thereof provided with cooling ribs, respectively. Resulting is an integrated cable connection between the motor control unit 24 and the fan motor 3 . This structural measure avoids electromagnetic interference fields during the operation of the fan motor 3 and increases the EMV tolerance of the hydraulic power pack 1 . The motor control unit 24 includes, in particular, a frequency converter that is parameterized individually in the presently shown embodiment by a separate operating unit and can be connected by a cable plug-in connection that is adjustable for the respective application of the fan motor 3 .
The fluid pump 14 conveys a temperature-control fluid in the presently shown embodiment, preferably a water-glycol mixture, and is embodied as an immersion pump. The fluid pump 14 therein can basically be designed, in terms of the construction type, more for a large volume flow or more for a correspondingly high pressure level of fluid 5 in a liquid-air cooling system circuit 6 for the machine unit 9 . The construction type of the fluid pump 14 can be, for example, a rotary pump or a pump with displacement elements like, for example, a roller pump or a rotary vane-type pump or a gear-type pump. Pump parts of the fluid pump 14 extend from and into the fluid tank 13 for the removal of fluid, not shown in further detail. In particular, the fluid pump 14 has a pump opening 25 for removing the fluid 5 from the fluid tank 13 . After the fluid 5 has run through the machine unit 9 or also a component 11 of the machine unit 9 , it is routed into the cellular radiator 19 via connection K. Cooled fluid 5 leaves the heat exchanger 19 directly via the actual value sensor and pipes 26 in the fluid tank 13 .
The temperature difference that is adjusted in the present embodiment is >5° Kelvin. A PID controller 27 in the motor control unit 24 serves particularly as a speed controller for the fan motor 3 . The distributor rail 7 , the motor control unit 24 as well as the PID controller 27 can also be combined into an automatic control system (not shown).
FIGS. 4 a to 4 d show logs of relevant operational parameters during the operation of the liquid-air cooling system 1 and of the machine unit 9 that is cooled by the same. For example, FIG. 4 a shows the heat output that is supplied by the machine unit 9 to the liquid-air cooling system 1 via the fluid 5 heated inside the machine unit 9 over a time interval from 0 to 6000 seconds. The supplied heat output fluctuates during this time interval between approximately 0.8 to 6.3 kW. During normal operation (time interval between 1000 seconds and 4,500 seconds), the supplied heat output fluctuates in the presently shown embodiment between 2.5 and 6.3 kW.
FIG. 4 b shows relevant temperature developments on the liquid-air cooling system plotted over the same time interval. The top curve in FIG. 4 b shows an embodiment of the temperature development of the temperature of fluid 5 at the inlet of the liquid-air cooling system 1 , meaning after it has left the machine unit 9 and prior to flowing into the heat exchanger 19 . The desired default value as depicted in the embodiment by the mentioned temperature fluctuates between approximately 28 and 32° C.
Below the top curve in FIG. 4 b is a curve of the fluid temperature of the fluid 5 after leaving the liquid-air cooling system 1 and after the cooling operation. This curve shows that the output temperature of the fluid 5 almost does not fluctuate at all after an adjustment process during a time interval of approximately 250 to 600 seconds, after which the temperature adjusts itself to approximately 27.8° C.
Below these mentioned temperature courses, FIG. 4 b depicts a volume flow V of the fluid 5 in the liquid-air cooling system 1 during the same time interval. The volume flow V is almost exactly 25 l/min. Below this curve, FIG. 4 b shows a typical course of a desired default value; presently a temperature Tb of the ambient air of the liquid-air cooling system 1 is shown. During the depicted time interval, the ambient air temperature fluctuates between 21 and 23° C. Correspondingly, with the liquid-air cooling system 1 , very exact temperature management of the components 11 of a machine unit 9 , for example in form of a machine tool spindle drive or a total machine unit 9 , such as a processing center or a machine tool, has become possible. The liquid-air cooling system 1 according to the invention is therefore able to provide for a marked improvement of the machine's accuracy during processing.
FIG. 4 c depicts, in the top curve, the course that the motor current of the fan motor 3 takes, while the bottom curve represents the course of the motor output of the liquid-air system of the fan motor 3 . In the depicted embodiment, the motor current fluctuates between approximately 1.2 and 2.2 Ampere, while the recorded motor output is between approximately 0 and 400 Watt.
FIG. 4 d is a representation of the speed fluctuation of the fan impeller 4 that is necessary to be able to depict the exact output temperature of fluid 5 , as shown in FIG. 4 b , after exiting the heat exchanger 19 . The speed of the fan impeller 4 therein fluctuates in a relatively wide range between approximately 200 and almost 1000 revolutions/min. The selected speed and/or speed range is also documented, such that the hydraulic power pack 1 is quite able to ensure, owing to comparatively minimal blade tip speeds of the fan blades, a minimal noise level during operation.
While one embodiment has been chosen to illustrate the invention, it will be understood by those skilled in the art that various changes and modifications can be made therein without departing from the scope of the invention as defined in the appended claims.
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A liquid-air cooling system ( 1 ) has at least one fan device ( 2 ) including at least one variable-speed fan motor ( 3 ) driving a fan impeller ( 4 ) to create a cooling power for a fluid ( 5 ) in a fluid cycle ( 6 ). To regulate the speed of the fan motor ( 3 ) by a control and/or regulation device ( 24 ), at least one actual value (Ta) downstream of a segmented heat exchanger ( 19 ) is compared to a predefined desired value (Tb). The control and/or regulation device ( 24 ) adjusts the cooling power according to the current power values of the respective machine unit ( 9 ).
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BACKGROUND OF THE INVENTION AND RELATED ART STATEMENT
[0001] The present invention relates to a cylinder head gasket placed between two members, such as a cylinder head and a cylinder block of an engine to seal therebetween. More specifically, even when the members on both sides are rubbed against each other and misaligned due to an external factor, such as a heat deformation of the members, the surface pressure on the end portion of a bore can be controlled not to rise, and indentation generated at the members can be reduced.
[0002] The cylinder head gasket is tightened by head bolts and seals fluid, such as combustion gas, oil, and coolant water in a state of being placed between the cylinder head and the cylinder block (cylinder body) of an automobile engine.
[0003] Also, as the weight and size of an engine have been reduced recently, the engine tends to have lower rigidity. Accordingly, when a large seal surface pressure is provided on the nearest part of the cylinder bore in order to assure a seal quality during the sealing of the cylinder head gasket, the cylinder bore is deformed because the engine member has lower rigidity. When the cylinder bore is deformed, a seal method, such as a bead or a folded portion, does not function well, and an adequate seal quality can not be obtained.
[0004] In order to provide an excellent seal quality by reducing the number of laminated plates, usage of the material, and the thickness of a whole gasket, and also by increasing the tightening pressure of the rim of a cylinder to the highest, metal gaskets, such as those shown in Japanese Patent Publications No. 8-121597 and No. 10-213227, form a wide folded portion (grommet portion) by directly folding back a secondary plate at the rim of the cylinder, and provide a full bead in two sheets of main plates which clamp the secondary plate. The full bead has a projection on the secondary plate side, and comes together with the folded portion.
[0005] However, in this kind of cylinder head gasket, the rim of the cylinder has the highest tightening pressure (seal pressure), so that the deformation of the cylinder bore can be accelerated. Also, the folded portion is directly folded back, and the folded diameter of the folded portion is small, thereby easily creating a crack.
[0006] In view of the problems described above, an object of the present invention is to provide a cylinder head gasket which can provide an excellent seal quality around the cylinder bore, and also can reduce the indentation around the cylinder bore which is generated at the engine member.
[0007] Further objects and advantages of the invention will be apparent from the following description of the invention.
SUMMARY OF THE INVENTION
[0008] In order to attain the objects described above, according to the present invention, a cylinder head gasket comprises a first metal plate with a folded portion around a cylinder bore; and a second metal plate which is laminated on the first metal plate and forms a full bead projecting to a first metal plate side. The projected portion of the full bead is disposed on the inner perimeter side of the end portion of the folded portion, and at least one or more sheets of secondary plate is inserted and disposed inside the folded portion.
[0009] According to the structure, by inserting and disposing the secondary plate inside the folded portion, the thickness of the folded portion can be made thicker, so that the curvature of the folded portion increases, hereby preventing the development of a crack.
[0010] In the cylinder head gasket, the second metal plate is laminated on the folded portion side of the first metal plate. In this structure, although the laminated position of the second metal plate comes to the side with the folded portion from the side without the folded portion, the above-mentioned same effect can be obtained.
[0011] In the cylinder head gasket, the thickness around the cylinder bore of the second metal plate is made smaller than half of the thickness of the folded portion. With this structure, even when a large tightening force is generated around the cylinder bore, the end portion of the second metal plate is entered into the rounded portion of the folded portion around the periphery of the cylinder bore, so that an excessive seal pressure is not added in the periphery of the cylinder bore, hereby controlling the deformation of the cylinder bore.
[0012] In the cylinder head gasket, a first secondary plate which is flat on the inner perimeter side of the end portion of the folded portion; and a ring-shape second secondary plate with a bead on the inner perimeter side of the end portion of the folded portion, are inserted and disposed inside the folded portion. Accordingly, the thickness of the folded portion can be adjusted by the first and second secondary plates. In addition, the compressibility of the folded portion can be increased by the bead of the second secondary plate, hereby preventing creep relaxation of the folded portion.
[0013] Also, if the projected portion of the second metal plate and the projected portion (contact portion with the first metal plate) of the bead of the second secondary plate are located in the same position in a plan view, a larger seal pressure can be formed. Also, if the above-mentioned two projected portions are misaligned in the plan view, the area of a relatively large seal pressure can be broadened while the maximum seal pressure is reduced.
[0014] Further, a third metal plate may be laminated on the first metal plate at a side opposite to the second metal plate. The third metal plate includes a full bead projecting toward the first metal plate. The full bead is disposed on the folded portion.
[0015] According to the cylinder head gasket, an excellent seal quality around the cylinder bore can be obtained, and by controlling the seal pressure around the periphery of each cylinder bore to be small, the deformation of the cylinder bore of the engine can be controlled.
[0016] Especially, even when the upper surface side and the lower surface side of the cylinder head gasket are rubbed against each other and misaligned due to an external factor, such as a heat deformation of a cylinder head or a cylinder block, the rise of the surface pressure on the tip of the bore can be controlled, thereby reducing indentation generated in the cylinder head or the cylinder block.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a fragmentary sectional view of a cylinder head gasket according to a first embodiment of the present invention;
[0018] FIG. 2 is an enlarged fragmentary sectional view of the proximity of a folded portion in FIG. 1 ;
[0019] FIG. 3 is a fragmentary sectional view of the cylinder head gasket according to a second embodiment of the present invention;
[0020] FIG. 4 is an enlarged fragmentary sectional view of the proximity of the folded portion in FIG. 3 ;
[0021] FIG. 5 is a fragmentary sectional view of the cylinder head gasket according to a third embodiment of the present invention; and
[0022] FIG. 6 is an enlarged fragmentary sectional view of the proximity of the folded portion in FIG. 5 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0023] Hereunder, a cylinder head gasket according to embodiments of the present invention will be described in detail with reference to the attached drawings. Incidentally, FIGS. 1-6 are schematic explanatory views, in which the thicknesses of plates, and sizes of the cylinder bores, the folded portions, and beads are different from actual ones, so that the cylinder head gaskets are enlarged for the sake of explanation.
[0024] The cylinder head gasket according to the invention is a metal gasket placed between engine members, such as a cylinder head and a cylinder block (cylinder body) of an engine to seal fluid, such as high-temperature and pressure combustion gas in the cylinder bore, and coolant water or oil in passages for the coolant water or cooling oil.
[0025] The cylinder head gasket is formed of single or multiple sheets of metal plates (metal substrates) made of soft steel, annealed stainless (annealed material), or stainless material (spring steel). Also, the cylinder head gasket is produced in a shape corresponding to the shape of the engine member, such as the cylinder block, and is provided with cylinder bores (combustion chamber holes), fluid holes for circulating the coolant water or engine oil, or bolt holes for tightening head bolts.
[0026] Firstly, the first embodiment of the invention will be explained. As shown in FIGS. 1 and 2 , the cylinder head gasket 1 of the first embodiment is comprised of two sheets of metal plates 10 , 20 , and three sheets of secondary plates 30 , 40 , 50 . The first metal plate 10 is made of annealed stainless, and the second metal plate 20 is made of stainless spring steel. Also, the first secondary plate 30 is made of soft steel or annealed stainless, and the second secondary plate 40 with a full bead 41 is made of stainless material. The third secondary plate 50 with the half bead 51 is made of annealed stainless.
[0027] The first metal plate 10 includes a folded portion or flange 11 which is made by folding back the first metal plate 10 around the cylinder bore 2 . The second metal plate 20 is laminated on the first metal plate 10 on the side where the first metal plate 10 does not include the folded portion 11 ; however, the second metal plate 20 is provided with a full bead 21 which has a projection on the first metal plate 10 side (inside), and a projected portion 21 a of the full bead 21 is disposed on the inner perimeter side of the end portion 11 a of the folded portion 11 .
[0028] Also, the first secondary plate 30 and the second secondary plate 40 are inserted and disposed inside the folded portion 11 . The first secondary plate 30 is formed flat on the inner perimeter side of the end portion 11 a of the folded portion 11 . The second secondary plate 40 is formed in a ring-shaped plate with the full bead 41 on the inner perimeter side of the end portion 11 a of the folded portion 11 . In a plan view, an end portion 40 a on the inner perimeter side of the second secondary plate 40 is located in the same position with an end portion 30 a on the inner perimeter side of the first secondary plate 30 . An end portion 40 b on the outer perimeter side of the second secondary plate 40 is located in the same position as the end portion 11 a of the folded portion 11 . The thickness tg of the folded portion 11 can be made thicker by inserting and disposing the secondary plates 30 , 40 , so that the curvature of the rounded portion 11 b of the folded portion 11 increases, thereby preventing the development of a crack.
[0029] In addition, the compressibility of the folded portion 11 can be increased by the full bead 41 of the second secondary plate 40 , thereby preventing creep relaxation of the folded portion 11 . Usually, a full bead is used for the bead 41 of the second secondary plate 40 ; however, a half bead may be used, and any bead can be used as long as the bead can prevent creep relaxation of the folded portion 11 . Also, a number of beads may be combined.
[0030] As shown in FIG. 2 , the plate thickness t 2 around the cylinder bore 2 of the second metal plate 20 is made smaller than the half th of the thickness tg of the folded portion 11 , i.e. t 2 <th (=tg/2). Also, the thickness tg of the folded portion 11 becomes thicker by inserting and disposing the secondary plates 30 , 40 into the folded portion 11 , so that the plate thickness t 2 around the cylinder bore 2 of the second metal plate 20 can be easily made smaller than the half th of the thickness tg of the folded portion 11 , respectively.
[0031] In addition, around the periphery of the water hole 3 , the second metal plate 20 includes half beads 22 , 23 . The direction of the projection of the half bead 23 is the same as that of the projected portion 41 a of the full bead 41 of the second secondary plate 40 . Also, the third secondary plate 50 forms the half bead 51 which projects to the opposite direction relative to the half bead 23 . These two half beads 23 , 51 are disposed in the same position in the plan view. More specifically, each sloping portion of the half beads 23 , 51 is disposed in such a way as to overlap each other in the plan view. Also, an end portion 50 a of the third secondary plate 50 which is located on the side of the perimeter of the cylinder bore 2 is positioned on the outer perimeter side compared to the end portion 11 a of the folded portion 11 .
[0032] Therefore, the rounded portion 11 b of the folded portion 11 of the first metal plate 10 , and the end portion 20 a of the second metal plate 20 , are aligned around the cylinder bore 2 . The end portions 10 b , 20 b of the first and second metal plates 10 , 20 , and the end portions 30 b , 50 b of the first and third secondary plates 30 , 50 , are aligned around the periphery of the water hole 3 .
[0033] According to the cylinder head gasket 1 with the above-mentioned structure, even when a large tightening force is generated around the cylinder bore 2 due to the relationship of thicknesses, the end portion 20 a of the second metal plate 20 is entered into the rounded portion 11 b side of the folded portion 11 around the periphery of the cylinder bore 2 . Accordingly, a large surface pressure is not generated around the periphery of the cylinder bore 2 , and the maximum surface pressure is generated on the outer perimeter side. As a result, an excessive seal pressure is not added in the periphery of the cylinder bore of the engine, thereby controlling the deformation of the cylinder bore. More specifically, by minimizing the maximum value of the surface pressure of the periphery of each cylinder bore 2 , the deformation of each cylinder bore can be prevented. Incidentally, the width of the folded portion 11 or shapes or sizes of the beads 21 , 41 can be obtained by a distribution of the surface pressure which is obtained by an experiment or calculation.
[0034] Also, when a large tightening force is not added, an appropriate seal pressure is added even in the periphery of the cylinder bore by the folded portion 11 and the full bead 21 , and moreover, seal pressure is added by a seal line which is formed by the full bead 2 on the outer perimeter side, thereby exerting an excellent seal quality.
[0035] With the first and second secondary plates 30 , 40 , the thickness tg of the folded portion 11 can be adjusted, and additionally, the compressibility of the folded portion 11 can be increased by the full bead 41 of the second secondary plate 40 , thereby preventing creep relaxation of the folded portion 11 . Usually, a full bead is used for the bead 41 of the second secondary plate 40 ; however, a half bead may be used, and any bead may be used as long as the bead can prevent creep relaxation of the folded portion 11 . Also, a number of beads may be combined.
[0036] Also, if the projected portion 21 a of the full bead 21 of the second metal plate 20 , and the projected portion (contact portion with the first metal plate) 41 a of the full bead 41 of the second secondary plate 40 are located in the same position in a plan view, a larger seal pressure can be generated. Also, if the above-mentioned two projected portions 21 a , 41 a are misaligned in the plan view, the area of a relatively large seal pressure can be broadened while the maximum seal pressure is reduced.
[0037] With this structure, even when the upper surface side and the lower surface side of the cylinder head gasket 1 are rubbed against each other and misaligned due to an external factor such as a heat deformation of a cylinder head or a cylinder block, the rise of the surface pressure on the end portion of the bore can be controlled, thereby reducing the indentation generated at the cylinder head or the cylinder block.
[0038] In the above, the full beads 21 , 41 are explained with the circular bead in the cross-sectional shape. However, the shape of the bead is not specially limited in this invention, and the cross-sectional shape may be a circular arc, sine (cosine), trapezoid, triangle (mountain shape), and the like.
[0039] Next, the second embodiment of the invention will be explained. As shown in FIGS. 3 and 4 , a cylinder head gasket 1 A of the second embodiment is comprised of two sheets of metal plates 10 , 20 A and three sheets of secondary plates 30 , 40 , 50 . The first metal plate 10 is made of annealed stainless, and the second metal plate 20 A is made of stainless spring steel. Also, the first secondary plate 30 is made of soft steel or annealed stainless, and the second secondary plate 40 including the full bead 41 is made of stainless material. In addition, the third secondary plate 50 including the half bead 51 is made of annealed stainless.
[0040] The first metal plate 10 includes the folded portion 11 which is made by folding back the first metal plate 10 around the cylinder bore 2 . The second metal plate 20 A is laminated in the folded portion 11 on the folded portion 11 side of the first metal plate 10 . However, a full bead 21 A which is projected to the first metal plate 10 side (inside) is provided in the second metal plate 20 A, and a projected portion 21 Aa of the full bead 21 A is located on the inner perimeter side of the end portion 11 a of the folded portion 11 .
[0041] Also, the first secondary plate 30 and the second secondary plate 40 are inserted and disposed inside the folded portion 11 . The first secondary plate 30 is formed flat on the inner perimeter side of the end portion 11 a of the folded portion 11 . The second secondary plate 40 is formed in a ring-shaped plate with the full bead 41 on the inner perimeter side of the end portion 11 a of the folded portion 11 . In a plan view, the end portion 40 a on the inner perimeter side of the second secondary plate 40 is located in the same position with the end portion 30 a on the inner perimeter side of the first secondary plate 30 . The end portion 40 b on the outer perimeter side of the second secondary plate 40 is located in the same position with the end portion 11 a of the folded portion 11 . The thickness tg of the folded portion 11 can be made thicker by inserting and disposing the secondary plates 30 , 40 , so that the curvature of the rounded portion 11 b of the folded portion 11 increases, thereby preventing the development of a crack. In addition, the compressibility of the folded portion 11 can be increased by the full bead 41 of the second secondary plate 40 , thereby preventing creep relaxation of the folded portion 11 . Usually, a full bead is used for the bead 41 of the second secondary plate 40 . However, a half bead may be used, and any bead can be used as long as the bead can prevent creep relaxation of the folded portion 11 . Also, some of beads may be combined.
[0042] In addition, as shown in FIG. 4 , the plate thickness t 2 around the cylinder bore 2 of the second metal plate 20 A is made smaller than the half th of the thickness tg of the folded portion 11 , i.e. t 2 <th (=tg/2). Incidentally, the thickness tg of the folded portion 11 becomes thicker by inserting and disposing the secondary plates 30 , 40 into the inside of the folded portion 11 , so that the plate thickness t 2 around the cylinder bore 2 of the second metal plate 20 A can easily be made smaller than the half th of the thickness tg of the folded portion 11 , respectively.
[0043] In addition, the second metal plate 20 A includes a half bead 22 A around the water hole 3 . The direction of the projection of the half bead 22 A is the same as that of the projected portion 41 a of the full bead 41 of the second secondary plate 40 . Also, the third secondary plate 50 forms the half bead 51 which has the opposite direction of the half bead 22 A. These two half beads 22 A, 51 are disposed in the same position in a plan view. More specifically, each sloping portion of each half bead 22 A, 51 is disposed in such a way as to overlap each other in the plan view. Also, the end portion 50 a of the third secondary plate 50 which is located on the periphery side of the cylinder bore 2 is positioned on the outer perimeter side compared to the end portion 11 a of the folded portion 11 .
[0044] Therefore, the rounded portion 11 b of the folded portion 11 of the first metal plate 10 , and the end portion 20 Aa of the second metal plate 20 A are aligned around the cylinder bore 2 . End portions 10 b , 20 Ab of the first and second metal plates 10 , 20 A, and end portions 30 b , 50 b of the first and third secondary plates 30 , 50 , are aligned around the periphery of the water hole 3 .
[0045] According to the cylinder head gasket 1 A with the above-mentioned structure, even when a large tightening force is generated around the cylinder bore 2 due to the relationship of the thicknesses, the end portion 20 Aa of the second metal plate 20 A is entered into the rounded portion 11 b side of the folded portion 11 around the periphery of the cylinder bore 2 . Accordingly, a large surface pressure is not generated around the periphery of the cylinder bore 2 , and the maximum surface pressure is generated on the outer perimeter side. As a result, an excessive seal pressure is not added in the periphery of the cylinder bore of the engine, thereby controlling the deformation of the cylinder bore. More specifically, by minimizing the maximum value of the surface pressure on the periphery of each cylinder bore 2 , the deformation of each cylinder bore can be prevented. Incidentally, the width of the folded portion 11 or shapes or sizes of the beads 21 A, 41 can be obtained by a distribution of the surface pressure which is obtained by an experiment or calculation.
[0046] Also, when a large tightening force is not added, an appropriate seal pressure is added even in the periphery of the cylinder bore by the folded portion 11 and the full bead 21 A, and moreover, a seal pressure is added by a seal line which is formed by the full bead 21 A on the outer perimeter side, thereby exerting an excellent seal quality.
[0047] With the first and second secondary plates 30 , 40 , the thickness tg of the folded portion 11 can be adjusted, and moreover, the compressibility of the folded portion 11 can be increased by the full bead 41 of the second secondary plate 40 , thereby preventing creep relaxation of the folded portion 11 . Usually, a full bead is used for the bead 41 of the second secondary plate 40 . However, a half bead may be used, and any bead may be used as long as the bead can prevent creep relaxation of the folded portion 11 . Also, some number of beads may be combined.
[0048] Also, if the projected portion 21 Aa of the full bead 21 A of the second metal plate 20 A, and the projected portion (contact portion with the first metal plate) 41 a of the full bead 41 of the second secondary plate 40 are located in the same position in a plan view, a larger seal pressure can be generated. Also, if the above-mentioned two projected portions 21 Aa, 41 a are misaligned in the plan view, the area of a relatively large seal pressure can be broadened while the maximum seal pressure is reduced.
[0049] With this structure, even when the upper surface side and the lower surface side of the cylinder head gasket 1 are rubbed against each other and misaligned due to an external factor, such as the heat deformation of the cylinder head or the cylinder block, the rise of the surface pressure on the end portion of the bore can be controlled, thereby reducing the indentation generated at the cylinder head or the cylinder block.
[0050] In the above, the full beads 21 A, 41 are explained with the circular bead of the cross-sectional shape. However, the shape of the bead is not specially limited in this invention, and the cross-sectional shape may be a circular arc, sine (cosine), trapezoid, triangle (mountain shape), and the like.
[0051] Next, the third embodiment of the invention will be explained. As shown in FIGS. 5 and 6 , a cylinder head gasket 1 B of the third embodiment is comprised of three sheets of metal plates 10 , 20 , 20 A and three sheets of secondary plates 30 , 40 , 50 . The first metal plate 10 is made of annealed stainless, and the second metal plates 20 , 20 A are made of stainless spring steel. Also, the first secondary plate 30 is made of soft steel or annealed stainless, and the second secondary plate 40 including the full bead 41 is made of stainless material. In addition, the third secondary plate 50 including the half bead 51 is made of annealed stainless.
[0052] The first metal plate 10 includes the folded portion 11 which is made by folding back the first metal plate 10 around the cylinder bore 2 . The second and third metal plates 20 , 20 A are disposed to sandwich the first metal plate 10 . Full beads 21 , 21 Aa which project to the first metal plate 10 side (inside) are provided in the second and third metal plates 20 , 20 A. Projected portion 21 a , 21 Aa of the full bead 21 , 21 A are located on the inner perimeter side of the end portion 11 a of the folded portion 11 .
[0053] Also, the first secondary plate 30 and the second secondary plate 40 are inserted and disposed inside the folded portion 11 . The first secondary plate 30 is formed flat on the inner perimeter side of the end portion 11 a of the folded portion 11 . The second secondary plate 40 is formed in a ring-shaped plate with the full bead 41 on the inner perimeter side of the end portion 11 a of the folded portion 11 . In a plan view, the end portion 40 a on the inner perimeter side of the second secondary plate 40 is located in the same position with the end portion 30 a on the inner perimeter side of the first secondary plate 30 . The end portion 40 b on the outer perimeter side of the second secondary plate 40 is located in the same position with the end portion 11 a of the folded portion 11 . The thickness tg of the folded portion 11 can be made thicker by inserting and disposing the secondary plates 30 , 40 , so that the curvature of the rounded portion 11 b of the folded portion 11 increases, thereby preventing the development of a crack. In addition, the compressibility of the folded portion 11 can be increased by the full bead 41 of the second secondary plate 40 , thereby preventing creep relaxation of the folded portion 11 . Usually, a full bead is used for the bead 41 of the second secondary plate 40 . However, a half bead may be used, and any bead can be used as long as the bead can prevent creep relaxation of the folded portion 11 . Also, some of beads may be combined.
[0054] In addition, as shown in FIG. 6 , each of the plate thicknesses t 2 , t 3 around the cylinder bore 2 of the second and third metal plates 20 A is made smaller than the half th of the thickness tg of the folded portion 11 , i.e. t 2 <th and t 3 <th (=tg/2). Incidentally, the thickness tg of the folded portion 11 becomes thicker by inserting and disposing the secondary plates 30 , 40 into the inside of the folded portion 11 , so that each of the plate thicknesses t 2 , t 3 around the cylinder bore 2 of the second and third metal plates 20 , 20 A can easily be made smaller than the half th of the thickness tg of the folded portion 11 , respectively.
[0055] In addition, the second metal plate 20 includes half beads 22 , 23 around the water hole 3 , and the third metal plate 20 A includes a half bead 22 A around the water hole 3 . The directions of the projections of the half bead 23 , 22 A are the same as the direction of the projected portion 41 a of the full bead 41 of the second secondary plate 40 . Also, the third secondary plate 50 forms the half bead 51 which has the opposite directions of the half beads 23 , 22 A. These three half beads 22 A, 23 , 51 are disposed in the same position in a plan view. More specifically, each sloping portion of each half bead 22 A, 23 , 51 is disposed in such a way as to overlap each other in the plan view. Also, the end portion of the third secondary plate 50 which is located on the periphery side of the cylinder bore 2 is positioned on the outer perimeter side compared to the end portion 11 a of the folded portion 11 .
[0056] Therefore, the rounded portion 11 b of the folded portion 11 of the first metal plate 10 , and the end portions 20 a , 20 Aa of the second and third metal plate 20 , 20 A are aligned around the cylinder bore 2 . End portions 10 b , 20 b , 20 Ab of the first, second and third metal plates 10 , 20 , 20 A, and end portions 30 b , 50 b of the first and third secondary plates 30 , 50 , are aligned around the periphery of the water hole 3 .
[0057] According to the cylinder head gasket 1 B with the above-mentioned structure, even when a large tightening force is generated around the cylinder bore 2 due to the relationship of the thicknesses, the end portions 20 a , 20 Aa of the second and third metal plates 20 , 20 A are entered into the rounded portion 11 b side of the folded portion 11 around the periphery of the cylinder bore 2 . Accordingly, a large surface pressure is not generated around the periphery of the cylinder bore 2 , and the maximum surface pressure is generated on the outer perimeter side. As a result, an excessive seal pressure is not added in the periphery of the cylinder bore of the engine, thereby controlling the deformation of the cylinder bore. More specifically, by minimizing the maximum value of the surface pressure on the periphery of each cylinder bore 2 , the deformation of each cylinder bore can be prevented. Incidentally, the width of the folded portion 11 or shapes or sizes of the beads 21 , 21 A, 41 can be obtained by a distribution of the surface pressure which is obtained by an experiment or calculation.
[0058] Also, when a large tightening force is not added, an appropriate seal pressure is added even in the periphery of the cylinder bore by the folded portion 11 and the full beads 21 , 21 A, and moreover, a seal pressure is added by a seal line which is formed by the full bead 21 , 21 A on the outer perimeter side, thereby exerting an excellent seal quality.
[0059] With the first and second secondary plates 30 , 40 , the thickness tg of the folded portion 11 can be adjusted, and moreover, the compressibility of the folded portion 11 can be increased by the full bead 41 of the second secondary plate 40 , thereby preventing creep relaxation of the folded portion 11 . Usually, a full bead is used for the bead 41 of the second secondary plate 40 . However, a half bead may be used, and any bead may be used as long as the bead can prevent creep relaxation of the folded portion 11 . Also, some number of beads may be combined.
[0060] Also, if the projected portions 21 a , 21 Aa of the full beads 21 , 21 A of the second and third metal plates 20 , 20 A, and the projected portion (contact portion with the first metal plate) 41 a of the full bead 41 of the second secondary plate 40 are located in the same position in a plan view, a larger seal pressure can be generated. Also, if the above-mentioned two or three projected portions 21 a , 21 Aa, 41 a are misaligned in the plan view, the area of a relatively large seal pressure can be broadened while the maximum seal pressure is reduced.
[0061] With this structure, even when the upper surface side and the lower surface side of the cylinder head gasket 1 are rubbed against each other and misaligned due to an external factor, such as the heat deformation of the cylinder head or the cylinder block, the rise of the surface pressure on the end portion of the bore can be controlled, thereby reducing the indentation generated at the cylinder head or the cylinder block.
[0062] In the above, the full beads 21 , 21 A, 41 are explained with the circular bead of the cross-sectional shape. However, the shape of the bead is not specially limited in this invention, and the cross-sectional shape may be a circular arc, sine (cosine), trapezoid, triangle (mountain shape), and the like.
[0063] The disclosures of Japanese Patent Applications No. 2006-136162 filed on May 16, 2006 and No. 2006-296644 filed on Oct. 31, 2006 are incorporated in the application.
[0064] While the invention has been explained with reference to the specific embodiments of the invention, the explanation is illustrative and the invention is limited only by the appended claims.
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A cylinder head gasket for an internal combustion engine with a cylinder bore and a fluid hole includes a first metal plate having a curved portion around the cylinder bore and a folded portion extending from the curved portion, and a second metal plate laminated on the first metal plate and having a first full bead projecting toward the first metal plate. The first full bead is disposed on the folded portion. At least one secondary plate is inserted inside the folded portion.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional patent application Ser. No. 60/889,687 filed on Feb. 13, 2007 and entitled “Trench Grate Assembly With Debris Chute.”
FIELD OF THE INVENTION
The present invention is directed to a grate assembly for topping a drainage trench, and more specifically, to a frame for supporting and retaining a grate structure over a drainage trench.
BACKGROUND OF THE INVENTION
Trenches for directing storm water to subterranean piping are commonly found in paved surfaces such as driveways and parking lots, and are typically found across vehicular entrances and interior surfaces of the pavement. To allow for vehicular travel over the trench, these trenches are typically covered by substantial grates or grating systems and assemblies that are cast into the pavement, for example, concrete.
Typical trench grate assemblies include two parts: a frame section that is cast into and retained by the pavement, and a grate section. The frame section comprises a metal component that is positioned over a ledge formed in the pavement when it is cast around the frame along the sides of the trench and is sized and dimensioned to receive a grate, that is usually generally rectangular in shape. The frame can be made up of many frame sections connected end to end to receive many grate sections end to end, so the trench can be quite long. The grate sections are typically fastened to the frame using bolts that extend through holes in the grate sections and are screwed into threaded holes in the frame.
Prior grates were sometimes difficult to attach securely to the frame. The threaded holes in the frame were blind holes or if through holes were closed by the concrete or other pavement into which the frame was cast. Debris could collect in the holes and when a bolt being threaded into the hole contacts debris proper tightening of the bolt becomes impossible. Once compressed, the debris could be difficult to remove and so fasteners could be left out or not completely tightened, resulting in a structure less structurally sound than intended, and would allow grates to be easily dislodged by traffic. The present invention addresses these problems.
SUMMARY OF THE INVENTION
In one aspect, the present invention provides a frame for retaining a trench grate over a drainage trench. The frame includes a substantially vertical support member having a sidewall for alignment along a wall of the drainage trench pavement into which the frame is cast, and a bearing flange extending substantially perpendicular to the sidewall for supporting a grate over the drainage trench, the bearing flange overlying the drainage trench pavement into which the frame is cast. The bearing flange includes at least one aperture for receiving a fastener for coupling the grate to the bearing flange, and a chute that substantially circumscribes an area below the aperture and that includes an opening directed inward toward the trench to direct debris collected through the aperture toward the trench to maintain the aperture in an open condition.
In another aspect of the invention, the chute can be angled toward the trench, and can also substantially circumscribe an area below the aperture. The interior of the chute, moreover, can be formed in the shape of compartment open at its front and closed on all other sides except the top into which the fastener hole opens.
The chute may, for example, be generally in the shape of a quarter sphere. The frame can also include an anchor element extending from a corner formed between the substantially vertical support member and the bearing flange in a direction away from the trench and into the pavement, to be cast and therefore securely retained in the pavement. The anchor member can include an aperture sized and dimensioned to have a rebar reinforcement rod threaded through it, which is also cast into the pavement for additional securement.
In yet another aspect of the invention, a frame for retaining a trench grate over a drainage trench is provided, including a support member extending along a wall of the drainage trench and including a substantially vertical sidewall. A substantially horizontal flange extends from the sidewall of the support member for supporting a grate in the drainage trench. Pavement encapsulates the outer side and bottom surfaces of the support member. A chute extends downward from the support member and is positioned below and substantially surrounding the aperture, which prevents pavement from filling in beneath the hole when the pavement is cast. A side of the chute faces inwardly toward the trench and includes an opening to allow debris received in the chute to be directed into the trench and to prevent debris from gathering in the bottom of the threaded hole. The opening in the chute can include a lower edge that is angled toward the trench.
In still another aspect of the invention, a drainage trench is provided, comprising a concrete structure having a bottom surface and first and second substantially parallel sidewalls, with shoulders at the upper ends of the sidewalls. A frame is embedded in the shoulders and includes a vertical support aligned along a side of each of the first and second parallel sidewalls and a substantially horizontal bearing flange extending from each of the vertical supports toward a center of the pavement trench. A grate, including a first plurality of spaced apertures, is received in the frame. A second plurality of spaced apertures is formed in the substantially horizontal bearing flange of the frame, and is configured for alignment with the first plurality of apertures for receiving fasteners to couple the grate to the frame. A chute is formed below each set of aligned apertures that has outer surfaces of its rear, side and bottom walls embedded in the pavement. Each chute includes an opening in its front wall, facing the trench, wherein debris collected in the aligned apertures can fall through the apertures into the chute and through the opening to maintain the apertures open. The inward edge of the opening is preferably in a plane and the plane is coplanar with the inward facing surface of the bearing flange to be sealed by a planar concrete form when concrete is poured around the frame. The chute can be ramped in the direction of the trench, substantially rounded in configuration, or can be shaped substantially as a quarter sphere.
Features and characteristics of the present invention will be apparent from the description which follows. In the detailed description below, preferred embodiments of the invention will be described with reference to the accompanying drawings. These embodiments do not represent the full scope of the invention. Rather the invention may be employed in other embodiments, and reference should therefore be made to the claims herein to determine the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of a trench assembly including a frame constructed in accordance with the present invention assembled as part of a drainage trench.
FIG. 2 is a cutaway side view of the trench assembly taken along the line 2 - 2 of FIG. 1 .
FIG. 3 is a cutaway view of the trench taken along line 3 - 3 of FIG. 1 .
FIG. 4 is a front view of a frame section of FIG. 1 .
FIG. 5 is a bottom view of a frame section of FIG. 1 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the Figures and more particularly to FIG. 1 , a top view of a trench grate assembly 10 constructed in accordance with the present invention is shown, as assembled over a drainage trench. The trench grate assembly 10 generally comprises a frame 14 , constructed from a plurality of frame sections 15 laid end to end, and a plurality of grate sections 16 that are received in the frame 14 . The frame 14 is constructed by aligning frame sections 15 end to end along a concrete form, e.g., sheets of plywood assembled so they create an open topped box, with the front or inward surfaces of the sections 15 against the outer sides of the concrete form, and pouring concrete around the sides of the form and the outside surfaces of the frame sections 15 . The concrete form, made of flat sheets, for example plywood, lays up flat against the front (or inward) surfaces 32 and 49 of the respective chute 26 and bearing flange 28 , which surfaces are flush with one another so as to simultaneously seat against the flat surface. This prevents concrete from flowing into the chute 26 or up over the flange 28 . The form, of course, prevents the concrete from flowing into the form so that when the concrete sets, the form can be removed leaving the open trench bordered at its top margin by the frame sections 15 , with the concrete side walls 51 of the trench substantially flush with the inward surfaces 32 and 49 of the respective chute 26 and flange 28 .
Anchors 22 are embedded in the pavement 21 surrounding the trench 12 , and may have steel re-bar threaded through them. The re-bar can be bent in a U or V shape, and the re-bar cast into the concrete along with the anchors 22 for additional holding force. The grate sections 16 are aligned end to end over the drainage trench 12 in the frame 14 , and each includes a plurality of threaded apertures 20 , which receive fasteners 18 in threaded engagement, for retaining the grate sections 16 on the frame 14 . Each fastener 18 is positioned over a debris chute 26 , a portion of the frame 15 that maintains an open area beneath the aperture 20 and fastener 18 , and directs debris from the bolt hole 23 toward the trench 12 .
Referring now to FIG. 2 , a cutaway side view of the trench grate assembly 10 of FIG. 1 taken along line 2 - 2 is shown. The frame sections 15 each include a substantially vertical member 25 coupled integrally (i.e., cast in one piece) to a horizontal flange 28 that extends along the length of the frame section 15 . A top surface 41 of the vertical member 25 aligns substantially with the top or roadway surface 43 of the pavement 21 , and the outside 27 and bottom 29 surfaces of the section 15 are cast in the concrete or other pavement. The bottom surface 29 is preferably angled downwardly away from the trench so that when the section 15 is driven over, it tends to wedge into the corner formed by the surrounding concrete. The generally horizontal flange 28 is positioned a distance from the top surface of the vertical member 25 selected to allow a grate section 16 to be positioned within the frame 14 with the top surface 45 of the grate section 16 substantially aligned with the top surfaces 41 and 43 of both the frame 14 and the pavement 21 , to provide a substantially continuous roadway surface. Anchor members 22 extend into the pavement 21 and are angled downward and away from the corner formed by the surfaces 27 and 29 . The anchor members 22 each include an aperture sized and dimensioned to receive a rebar reinforcement member, as described above.
Referring now to FIG. 3 , a cross-sectional view of the trench 12 taken along the line 3 - 3 of FIG. 1 through the debris chute 26 in the frame section 15 is shown. The debris chute 26 is positioned adjacent an aperture 23 in the frame section 15 that is aligned with an aperture 20 in the grate section 16 for receiving a threaded fastener 18 to couple the grate section 16 to the frame section 15 . The debris chute 26 is formed below the bottom surface of the horizontal flange 28 and, referring now also to FIG. 4 , substantially circumscribes the aligned holes 20 and 23 . An interior surface 33 of the chute 26 is directed toward an opening 31 , and is substantially rounded in cross-section such that a corner between a back wall and a lower surface of the debris chute 26 is curved and sloped toward the opening 31 , forcing dirt and debris collected in the debris chute 26 through the opening 31 and into the trench 12 , to maintain the aperture 23 substantially open. The lip of the lower surface 30 positioned adjacent the trench 12 is also rounded, again to force dirt and debris from the chute 26 . As shown here, the interior surface 33 is shaped as a compartment with a single open side, on its inward side, and the threaded bolt hole 23 opening in its top side. More particularly, the chute 26 is cupped, and may be substantially shaped as a portion of a sphere, and more specifically as a quarter of a sphere-like surface. Referring still to FIG. 4 , the opening 31 of the debris chute 26 , therefore, is generally a cross section of a sphere and therefore substantially semi-circular in shape, with an upper surface formed by the flange 28 . Concrete or other paving material encapsulates the sides, bottom and back of the chute 26 , and is not over the opening 31 . Opening 31 is defined by edge surface 32 of the chute 26 around the opening 31 . Surface 32 is co-planar with the vertical edge surface 49 at the front of the flange 28 . Being coplanar allows these surfaces 31 and 49 to butt up against the flat side of a concrete form, typically a plywood surface, to prevent concrete from flowing into the chute 26 or up over the flange 28 when the concrete is poured. The concrete sidewalls 51 therefore are cast substantially flush, i.e. substantially co-planar at least where they meet the edges 32 and 49 , with the front edges 32 and 49 of the respective chute 26 and flange 28 .
Referring now to FIG. 5 , a bottom view of the frame section 15 is shown. Debris chutes 26 are located adjacent apertures 23 for receiving a threaded fastener 18 , and include a rounded inner surface substantially closed except at the front opening 31 and top hole 23 , as described above with reference to FIGS. 4 and 5 .
Referring still to FIG. 5 , the frame section 15 is again shown with anchor members 22 , including apertures 24 sized and dimensioned to receive a rebar reinforcement. The anchor members 22 can couple the frame to wood or other framing members during construction of the trench 12 , for retaining the corresponding frame section 15 in the pavement 21 and anchoring the frame section 15 in position when they are set in cured concrete, particularly if re-bar is threaded through them.
Referring again to FIG. 3 , it can be seen that, after the fastener 18 is removed from apertures 20 and 23 , dirt and debris falling into the aligned apertures 20 and 23 will be directed to the debris chute 26 , thereby preventing the accumulation of debris which could clog the holes 20 and 23 , prevent the insertion of the fastener 18 , and thereby inhibit either assembly or re-assembly of the frame and grate assembly 10 .
Although a preferred embodiment of the invention has been described in considerable detail above, many modifications and variations to the preferred embodiment will be apparent to a person of ordinary skill in the art. For example, although the interior of the chute is shown and described as forming a portion of a sphere, the interior surface can be angled toward the drainage trench in various ways, and formed in various shapes useful for directing debris toward the trench. For example, the interior of the chute can be formed as a tube, or ramped or angled, toward the trench in a number of different ways which will allow debris to be directed into the trench.
Preferably, as shown in FIG. 1 , an aperture 20 is provided adjacent each corner of the grate section 16 to receive a fastener 18 . Various other types of locking and coupling devices, however, could also be used for securing the grate sections 16 to the frame 14 . Furthermore, although the frame sections 15 are shown here as separate and independent pieces, adjacent frame sections 15 can also be coupled together. For example, adjacent frame sections can include apertures for receiving threaded or other fasteners or coupling devices.
A preferred embodiment of the invention has been described in considerable detail. Many modifications and variations will be apparent to persons skilled in the art. Therefore, the invention should not be limited to the embodiment described but should be defined by the claims that follow.
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A frame for retaining a grate over a trench for directing storm water to subterranean basins includes a frame that is embedded in the concrete surrounding the trench. The frame includes a vertical support that is sized and dimensioned to abut the pavement wall of the trench, and a horizontal flange extending from the vertical support to support a grate. The horizontal flange and grate each include a plurality of apertures that are configured to be aligned to receive coupling devices for securing the grate to the frame. A chute is positioned beneath each aperture in the frame to direct debris from the aperture to the trench.
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[0001] This application claims the benefit of the filing date of U.S. Provisional Application No. 60/944,916, filed Jun. 19, 2007.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to wall plates used to convey electric signals through premise wiring systems, and more particularly to a wall plate assembly with an integrated universal serial bus (USB) module for USB extension without the need for an external power supply.
[0003] USBs are an increasingly popular way to connect computers to peripheral devices, such as data input/output, portable memory devices and audio/visual equipment. By placing the issues associated with linking dissimilar devices into on-board software (or protocol), the USB makes connection between a hub (or source) and function (or device). USBs can be powered so that they regenerate signals, thereby allowing great lengths between hub and function devices.
[0004] Wall plates are commonly used to terminate premise wiring. In one general form, the wiring acts as a signal carrier for electrical signals, while in a specific form is capable of conveying audio, video and related data signals between a signal source (such as a computer, audio, video or combination device) and the wall plate. Audio, video and data devices (such as displays, monitors, digital video disk (DVD) players, compact disk (CD) players, video tape recorders or the like) can be plugged into the outlet of the wall plate to complete the signal path. These, as well as other device that may employ USB electronics, connections and related circuitry, may be placed at distances remote from a host, often at distances far greater than that which a USB signal is able to extend.
[0005] In such circumstances, it may be necessary to boost or otherwise extend the USB signal. In one form of signal extension, the USB electronics are coupled to an external power source, such as a conventional AC source in what is referred to as a self-powered configuration. Such coupling allows the needed increase in range, but does so through additional wiring that may be prohibitive from a space, cost and related complexity perspective. In another form, the USB electronics draw all of their needed power from the USB connection itself, in what is known as a bus-powered configuration. Typically, the USB electronics are incorporated into one or more separate modular units that provides the extension in range, and includes a transmitter unit (for example, at the host end) and a receiver unit (for example, at the device end). Each unit is in turn connected to a wall plate so that devices requiring USB connection can do so through the wall plate. While useful for its intended purpose, such designs are problematic in that special attachment schemes between the USB electronics and the wall plate are necessary. For example, dongle and related connectivity cables are required. As with the external-powered approach discussed above, the self-powered approach makes the wall plate assembly bulky and expensive. In either approach, the presence of separately attached, exposed and removable components also renders the wall plates susceptible to damage during transport, installation nor the like.
[0006] It is therefore desirable that a more efficient, lower-cost, more reliable approach to connecting USB equipment through a wall plate be developed. It is additionally desirable that a compact, easy-to-use wall plate assembly incorporating self-powered USB features for extended range be developed. It is further desirable that an approach to packaging USB signal-extending circuitry such that the circuitry is an integral part of a wall plate assembly.
BRIEF SUMMARY OF THE INVENTION
[0007] These desires are met by the present invention, where a wall plate assembly and a method of connecting USB-compatible wiring is disclosed. According to a first aspect of the invention, a wall plate assembly includes USB-compatible hardware and related circuitry mounted onto a wall plate such that the wall plate and module define a single unit that is mechanically and electrically integrated. In the present context, disparate components, members, devices or related equipment are considered to define a mechanically integrated or integral whole or unit when such components are combined in such a way as to make them rigidly secured to one another such that they are integral in a functional sense. Means such as fastening and welding may be indicative of such integral structure if, as a result of such fastening, welding or the like, they produce an article that is of substantially unitary or one-piece construction. Generally, the presence of separate, readily removable and attachable components (such as hand-connected dongle cables or related wires, as well as those components situated on an outer surface or periphery of the unit) would be destructive of such an integral construction. Similarly, separate components are considered to be electrically integrated when the connection between them is through predominantly non-separable components. Thus, cables with quick-connect or related non-permanent features are considered to be non-integral, whereas hardwired, adhesively mounted, soldered or trace-connected (such as on a printed circuit board) components are considered to be integral.
[0008] The wall plate assembly includes a wall plate defining a face (for example a front face) with one or more USB connectors formed in the face, a wall mounting member, a circuit board and a housing configured to substantially contain the circuit board. The circuit board includes USB extender circuitry and an electrical interface extending from the circuit board and cooperative with the extender circuitry such that upon coupling of the interface to a first USB-compatible component, a signal may be operated upon by the extender circuitry while being transmitted between first and second USB-compatible components, where one is connected directly to the connector and the other directly to the interface. In the present context, the term “substantially” refers to an arrangement of elements or features that, while in theory would be expected to exhibit exact correspondence or behavior, may, in practice embody something less than exact. As such, the term denotes the degree by which a quantitative value, measurement or other related representation may vary from a stated reference without resulting in a change in the basic function of the subject matter at issue. By having the extender circuitry be directly secured both electrically and mechanically to one or more other components within the assembly, such as the connector, mounting member, wall plate, circuit board or housing, it takes on an integrated structure not possible with configurations where the circuitry can be readily attached and detached.
[0009] Optionally, the wall mounting member is configured as a bracket that can mount to a wall structure by accepting a fastener through it. The extender circuitry can be formed on the circuit board, or can be mounted directly to the circuit board. In either event, it is desirable to avoid cables with quick-connect and other relatively non-permanent connectivity. In one form, the wall mounting member and the wall plate are formed as a unitary structure, while in another, they can be permanently affixed to one another. In the present context, terms implying “permanent” or “semi-permanent” connectivity between components include situations where that which is joined is not intended on becoming separated such that in the process of such separation, damage is done to either or both of them, or the structural or electrical properties are defeated or at least severely curtailed. The assembly may further include one or more posts extending between the circuit board and the wall plate to create a spaced relationship between them. In another optional form, the wall plate, wall mounting member, circuit board and housing are rigidly affixed to one another. The housing may be formed around the printed circuit board on the back of the wall plate such that it defines a substantially closed, rectangular containment (such as a simple box). Furthermore, the box may be made from an inexpensive, lightweight material (such as plastic), or may be made from a metal-based material so that the housing acts as an electromagnetic shield that can substantially enclose the circuit board. In either material configuration, it also has an aperture formed therein to allow the rear coupling to be easily accessed by a jack or related terminus point of USB wiring being fed to the wall plate assembly. The housing may additionally define a recess in the housing's otherwise substantially rectangular shaped outer dimension. In this way, the aperture discussed above defines a cutout for the coupling. The extender circuitry may be permanently affixed to the circuit board or connector. The assembly may also include one or both of a transmitter and a receiver so that USB signals coming into or leaving the assembly can be appropriately conveyed.
[0010] According to another aspect of the invention, a bus-powered USB wiring system is disclosed. The system includes an assembly generally similar to that discussed in the previous aspect, and further includes at least one wire, cable or similar electrically-conductive signal carrier to convey a USB-compatible signal. The wire has a proximal end configured to connect to a USB host and a distal end configured to connect to a USB device. The assembly includes a wall plate defining a face with one or more USB connectors formed in it. The assembly further includes a wall mounting member (for example, a bracket) and a circuit board connected to one or both of the wall plate and the wall mounting member. The circuit board includes USB extender circuitry and an electrical interface, where the latter is mounted to or otherwise extends from the circuit board so that upon coupling of the interface to the wire, a signal that is transmitted between the host and device through the wire may be operated upon by the extender circuitry while passing through the wall plate assembly. The extender circuitry is electrically coupled to one of the connector and the interface such that it receives its operating electrical power from a respective one of the host and device. In addition, the assembly includes a housing that acts as an enclosure or container for the circuit board, extender circuitry and electrical interface. The housing may include cutouts or apertures formed therein to allow connection of the wire to the interface and circuit board.
[0011] Optional features include connecting numerous wall plate assemblies together. In addition, one of the wall plate assemblies may further include or be connected to a transmitter, while a second may include or be connected to a receiver. In one form, the transmitter is placed serially upstream of the receiver. For example, if the wiring is used to support a computer system, the transmitter can be located at or with the computer such that one or more wall plate assemblies can include receivers and be linked to the transmitter through appropriate cable or related wiring. The wire used to convey the USB-compatible signal may be an industry-standard variety, such as an RJ CAT 5 cable.
[0012] According to another aspect of the invention, a method of connecting USB-based components through a wall plate assembly is disclosed. The method includes arranging the wiring to include a quick-connect coupling that can be connected to a complementary quick-connect coupling situated on a wall plate assembly. The wall plate assembly includes (in addition to the complementary coupling) a USB module mounted to a wall plate such that the module and plate form an integral whole. Optionally, connection between the wall plate assembly to one or more USB wires can be through complementary quick-connect couplings. Such coupling may be permanently attached to the USB module, which is preferably formed on or as part of a printed circuit board.
[0013] Optionally, the method further includes securing at least one of the wall plate, wall mounting member and circuit board to a housing; in this way, the housing can substantially contain the circuit board. In another particular form, electric power can be provided to the wall plate assembly from the host. More particularly, the first component can be a computer, including desktop, laptop or other related variants. The second component (which is preferably associated with the device) can be a printer, video display, cellular telephone, digital camera, scanner, bar code reader, modem, personal digital assistant and an integrated services digital network (ISDN) terminal adapter.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0014] The following detailed description of specific embodiments of the present invention can be best understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which:
[0015] FIG. 1 illustrates a schematic view of a wall plate assembly with USB connectivity according to one form of the prior art;
[0016] FIG. 2A illustrates a forward view of a wall plate assembly with separately attached USB electronics according to another form of the prior art;
[0017] FIG. 2B illustrates a rearward view of the wall plate assembly of FIG. 2A , highlighting the separate USB extender;
[0018] FIG. 3A illustrates a generally rearward view of a wall plate assembly according to an embodiment of the present invention, shown coupled to a USB wire;
[0019] FIG. 3B illustrates a rearward perspective view of the wall plate assembly of FIG. 3A ;
[0020] FIG. 4A illustrates a front view of a wall plate according to an aspect of the present invention with a Type A USB connector;
[0021] FIG. 4B illustrates a side view of the wall plate of FIG. 4A ;
[0022] FIG. 4C illustrates the side view of the wall plate of FIG. 4A with a housing covering the back thereof;
[0023] FIG. 4D illustrates a front view of a wall plate according to an aspect of the present invention with a Type B USB connector;
[0024] FIG. 4E illustrates a side view of the wall plate of FIG. 4D ;
[0025] FIG. 4F illustrates a side view of the wall plate of FIG. 4D with a housing covering the back thereof;
[0026] FIG. 5 shows a house using premise wiring and one embodiment of the wall plate assembly of the present invention; and
[0027] FIG. 6 shows a USB-compatible wiring system according to an embodiment of the present invention.
DETAILED DESCRIPTION
[0028] USB-configured wall plates can be used to provide asymmetric connectivity between a USB-compatible host and a USB-compatible remote device, as well as act as a hub for numerous USB ports in versions that include numerous connectors. In this latter configuration, they can function in a manner generally similar to external (i.e., stand-alone) USB hubs. In any event, USB-configured wall plates generally include self-power or bus power, as previously discussed. Referring first to FIG. 1 , the assembly of a wall plate 10 according to a self-powered form of the prior art is shown. The wall plate 10 includes a first (forward-facing) surface, second (i.e., rearward-facing) surface, a printed circuit board 12 and USB hub circuit 14 mounted thereto. A USB connector 22 extends from the printed circuit board 12 through the first and second surfaces of the wall plate 10 , as does an indicator light 24 . The USB hub circuit 14 is structured to permit numerous USB devices to be connected together and to a host computer USB port or another hub circuit (neither of which are shown). Although the wall plate 10 is shown with a single USB connector 22 , it will be appreciated by those skilled in the art that USB hub circuit 14 , operating in conjunction with numerous USB connectors 22 formed in the forward-facing surface of wall plate 10 , can be used to connect multiple USB devices. It will also be appreciated by those skilled in the art that a variant of the wall plate 10 without a USB hub circuit may also be employed for situations where the need for multiple connectors or ports is not present.
[0029] As mentioned above, the configuration such as that depicted in FIG. 1 is referred to as a self-powered wall plate in that receives electrical power from external power supply 18 that feeds a transformer 20 and local USB power supply 16 . The entire assembly may be placed inside a junction box (not shown) that in turn may be mounted within an opening formed in a wall (not shown). The combination of the external power supply 18 , transformer 20 and local USB power supply 16 , while allowing USB range to be extended, occupies a significant amount of volume in the assembly, as separate lines to provide the external power are needed. Thus, while such a configuration can be used for multiple USB devices, the additional wiring associated with the power supply 18 , coupled with the wiring needed for the numerous connectors or ports, causes significant increases in size or complexity.
[0030] Referring next to FIGS. 2A and 2B , the assembly of a wall plate 50 according to the bus-powered form of the prior art is shown. As with the self-powered version discussed above, wall plate 50 allows a USB to be extended over greater operating lengths, as without the signal boosting made possible by the externally-powered USB connection of FIG. 1 , or the bus-powered version shown in FIGS. 2A and 2B , the length of wiring used to establish the connection is limited, typically to around five meters in length. A USB extender 62 , such as that shown in with particularity in FIG. 2B and discussed in more detail below, can increase the length between a USB host and device by up to one hundred and fifty feet or more, as can the device of FIG. 1 . Referring with particularity to FIG. 2A , a first (forward-facing) surface 50 A is shown with various connectors mounted therein, including a network connector 54 , computer connector 56 , audio connector 58 and USB connector 60 of the Type B variety. Power for the USB is delivered through USB connector 60 from a host, such as a computer (not shown).
[0031] Referring with particularity to FIG. 2B , a second (rearward-facing) surface 50 B is shown with the rearward portions of the network, computer, audio and USB connectors 54 , 56 , 58 and 60 projecting therethrough. The USB extender 62 is in the form of a self-contained modular unit that is attached to the rearward-facing surface 50 B, and acts as a receiver to accept appropriate USB signals from a complementary transmitter (not shown). Such an extender may function in a manner generally similar to that of the device of FIG. 1 , with the exception of how it derives its operating power, where instead of taking power from an external source, it takes it from the upstream USB host. In addition to containing extender circuitry, the USB extender 62 may also include DC power conditioning circuitry in order to ensure proper voltage is delivered to the remote device.
[0032] A separate dongle cable 64 is used to establish electrical connectivity between the USB connector 60 and the USB extender 62 . The dongle cable 64 terminates on at least one end with a quick-connect coupling. USB extender 62 is not integrated into wall plate 50 , as it is secured (if at all) to the rear surface of wall plate 50 through a limited contact, which may be glued, fastened (such as by screws that extend through the wall plate 50 and into complementary threads formed in the USB connector 62 ), snap-fit or otherwise mechanically joined together. By these features, the wall plate 50 is not truly integrated, in that while it possesses the equipment necessary to establish signal connectivity between a host and device, the modular, removable nature of the connection between the wall plate 50 and the USB extender 62 belies a lack of permanence that is associated with integration. Furthermore, the dongle cable 64 is packaged in such a way as to leave exposed many of the delicate connecting features. For example, dongle cable 64 is left exposed, such that upon installation or transport, its signal connection between the USB connector 60 and USB extender 62 is susceptible to damage or becoming disconnected. Further, the length of the dongle cable 64 (which my be up to six inches or more) is such that it can extend beyond the footprint of the wall plate 50 , thereby making the installer's job more difficult. It is worth noting that merely covering the exposed components, such as dongle cable 64 and USB extender 62 , with a junction box or related cover is not sufficient in and of itself to establish the requisite degree of integration, as their degree of connectivity to at least each other, as well as to wall plate 50 , would remain unchanged.
[0033] Referring next to FIGS. 3A and 3B , the back (or rear) side of a wall plate assembly 100 according to an aspect of the present invention is shown. In it, a wall plate 110 is shown supported by the mounting bracket (also referred to as a wall mounting member) 120 . The bracket 120 includes apertures that allow a screw or related fastener to pass therethrough for engagement with a stud, wall board or other structural member in the wall. A housing 130 with partial recess 135 is used to contain components of assembly 100 inside. Wiring 150 (shown presently as twisted pair) supplies signals from a host or other device (neither of which are shown) to the assembly 100 , connected through a jack 160 that is shaped to mechanically cooperate (such as by snap-fit or other resilient connection) to an electrical interface 195 (also known as an outlet, described below) formed on a printed circuit board 180 such that it can cooperate with wiring 150 and jack 160 through a cutout formed in recess 135 . The nature of the recess 135 is such that when external wiring 150 and ancillary connectors (such as jack 160 ) engage the housing 130 , they do so without increasing the footprint of wall plate assembly 100 . By having housing 130 contain all of the electrical USB and related signal connectors, ports and associated wiring, the robustness of assembly 100 is enhanced, as the likelihood of damage during installation is reduced by the presence of a rigid structure with electrical connections achieved through relatively-unexposed flush mounting. Unlike the non-integrated configurations of the prior art, circuit board 180 preferably includes the USB extender circuitry directly thereon, thereby minimizing the chance of disparate components and their connections from coming apart during shipping, storing or installation.
[0034] Referring next to FIGS. 4A through 4F , front and side views of the wall plate assembly of FIGS. 3A and 3B are shown, where one of each of the side views shows the wall plate 110 with the housing 130 attached, and the other without, the latter thereby exposing the printed circuit board 180 and a coupling in the form of electrical interface 195 that is compatible with jack 160 such that the two form a snap-fit or related connection. Printed circuit board 180 is mounted to either the bracket 120 or to the rear surface of the wall plate 110 (this latter configuration as shown in the side views) through posts 190 . Soldering, adhesives, friction fit or related connection can be used to promote an integral relationship between the printed circuit board 180 and wall plate 110 or bracket 120 . Housing 130 is mounted to either or both of the bracket 120 and wall plate 110 through a series of fasteners 140 (which may be in the form of screws, rivets, adhesives or the like), while the electrical interface 195 and USB extender electronics are mounted to or formed in printed circuit board 180 in such a way as to form an integrated whole with one or more of the bracket 120 , wall plate 110 and housing 130 .
[0035] As can be seen in the side views, the USB connectors (collectively 170 , but shown as a Type A connector 170 A in FIGS. 4A through 4C and a Type B connector 170 B in FIGS. 4D through 4F ) extend through the wall plate 110 to allow user access to the front side of the wall plate 110 . Although Type A and Type B connectors are shown, it will be appreciated by those skilled in the art that other USB-compatible connectors may be used, such as micro USB connectors and mini USB connectors. Either of the connectors 170 A, 170 B are also electrically connected to the electrical interface 195 through the printed circuit board 180 such that signals generated by a USB host are passed to a USB device through the connectors 170 A, 170 B, printed circuit board 180 and electrical interface 195 , the last of which includes a proximal end and a distal end, where the proximal end is in electrical communication with the printed circuit board 180 , while distal end electrically connects to the jack 160 , such as shown in FIGS. 3A and 3B . The printed circuit board 180 may contain (or have mounted thereon) the USB electronics and related circuitry, such as DC conditioning circuits or the like. The quick-connect nature of the electrical interface 195 , such as by a resiliently biased spring or related snap-fit connection 161 , provides a secure and fast coupling with the mating quick-connect electrical connector of the jack 160 .
[0036] One valuable attribute of the wall plate 110 of the present invention is its modularity made possible by its integral, self-contained construction. The housing 130 may be formed from a plastic case (for example, a gang box, also referred to as a junction box) that also houses the terminus point (for example, the distal end of the electrical interface 195 ) of USB wiring 150 . Other materials (for example, metal) may be used to provide additional capabilities as needed. For example, in situations requiring an enhanced level of electromagnetic shielding, a metal housing 130 may be used. Although shown for a single USB connector 170 , it will be appreciated by those skilled in the art that additional electrical interfaces (not shown) and associated cutouts (also not shown) may be employed in the integrated approach discussed herein.
[0037] Printed circuit board 180 is of a generally planar construction and is fabricated by techniques well-known to those skilled in the art. The electronics that make up the USB extender may be mounted to or formed on the circuit board 180 , thereby removing the need for a separate modular container, such as that shown in FIG. 2B . In one form, the circuit board 180 is substantially coextensive with the wall plate 110 or bracket 120 to better enable the incoming wiring 150 and accompanying jack 160 to line up with the appropriate wiring or circuitry on the circuit board 180 . The circuit board 180 can be encased in the aforementioned housing 130 , and by virtue of its direct connection between the USB connector 170 and the electrical interface 195 , reduces the likelihood of wiring disconnects under normal shipping and installation. For example, the need for a separate dongle or related cable is removed, thereby avoiding the difficulty of keeping such components connected to one another during installation and use. By having the USB electronics formed on the printed circuit board 180 , which is in turn integral with the bracket 120 , wall plate 110 and housing 130 within the wall plate assembly 100 , reliable, volumetrically efficient USB connectivity is promoted.
[0038] Referring next to FIGS. 5 and 6 , the placement of integral wall plate assemblies 100 within a wiring system in a dwelling 200 , as well as a notional bus-powered USB wiring system according to an embodiment of the present invention is shown. Referring with particularity to FIG. 5 , while the term “dwelling” is shown as a home, dormitory, apartment or other residence where people live, it will be appreciated that it may also be used to describe an office, factory, classroom or other commercial, institutional or manufacturing facility where people learn, work or the like. The wiring system can be responsive to input from an electrical device, such as a central control panel 230 (which may be connected to a multimedia system 240 or the like) or computer 210 , the latter acting as a transmitter of USB signals. As shown, wall plate assemblies 100 can form either a terminus point or an intermediary point within wiring system. One form of device that can benefit from a USB connection according to the present invention is a monitor 220 . Monitors 220 can be placed in various locations within dwelling 200 to facilitate the transmission of various signals (for example, audio/visual signals). In another form (not shown), computer peripheral equipment, such as printers, monitors or the like, can be placed remotely relative to the computer 210 . Referring with particularity to FIG. 6 , wall plate assemblies 100 are connected between a transmitter shown in the form of the USB-compatible computer 210 , and a receiver shown in the form of a USB hub 310 , although it will be appreciated that the receiver can be any number of USB-compatible devices, such as hard drive enclosure, printer, projector, white boards or the like. USB-compatible wiring 150 (for example, the aforementioned RJ45 CAT 5 cable) is used to interconnect the various devices. In the form shown, one of the wall plate assemblies 100 includes a USB Type B connector 170 B signally adjacent the source provided by computer 210 , while another of the wall plate assemblies 100 includes a USB Type A connector 170 A signally adjacent the (receiver) device 310 .
[0039] Having described the invention in detail and by reference to specific embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims. More specifically, although some aspects of the present invention are identified herein as preferred or particularly advantageous, it is contemplated that the present invention is not necessarily limited to these preferred aspects of the invention.
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A wall plate assembly including a wall plate with an integrated USB module. The assembly includes a USB connector and printed circuit board formed together on the wall plate as an integral whole. By placing USB extender circuitry directly on the printed circuit board, rather than in a separate housing, the present assembly can maintain its bus-powered attributes without the bulk of a separate extender housing. A quick-connect coupling enables fast electrical connection and disconnection with a complementary quick-connect coupling on a USB wire.
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This application is the national phase under 35 U.S.C. § 371 of PCT International Application No. PCT/DE02/04284 which has an International filing date of Nov. 21, 2002, which designated the United States of America and which claims priority on German Patent Application number DE 101 58 758.9 filed Nov. 29, 2001, the entire contents of which are hereby incorporated herein by reference.
FIELD OF THE INVENTION
The invention generally relates to a marine or boat propulsion system, having at least one vessel propeller. Preferably, it includes at least one electric motor, by which the at least one vessel propeller can be driven, and a converter-fed electrical power supply, by which the at least one electric motor can be supplied with electric power. It further preferably has at least one drive machine and at least one generator which can be driven by it. The at least one electric motor and the at least one generator for supplying electrical power are preferably in the form of three-phase synchronous machines.
BACKGROUND OF THE INVENTION
Diesel/electric marine propulsion systems are known, whose power supply has synchronous generators which are accommodated at some suitable point in the vessel's hull, and which themselves feed converter-fed synchronous or else asynchronous motors. The electric motors which drive the vessel propellers may, for example, be arranged as in-board motors, and may drive the vessel propellers via shaft systems.
Furthermore, pod propulsion systems are known, which have a synchronous motor with permanent-magnet excitation, arranged in a motor gondola which can be rotated. The motor gondola is arranged outside the vessel's hull and may have one or two vessel screws. The heat losses from the electric motor are in this case dissipated solely by the external surface of the motor gondola to the sea water. The asynchronous motors and generators have air/water heat exchangers.
Furthermore, JP 63217969 and JP 04304159 disclose marine propulsion systems for two vessel propellers including an associated so-called “homopolar motor”, which comprises two disc rotors or cylindrical rotors through which direct current flows in opposite directions via brushes, and in which a torque is produced in the field of a superconducting coil.
SUMMARY OF THE INVENTION
An embodiment of the invention is based on an object of further-developing the marine propulsion system such that it can be designed to be at least one of more space-saving, more weight-saving, and/or to be more efficient.
According to an embodiment of the invention, an object may be achieved in that the at least one electric motor (which is in the form of a three-phase synchronous machine) and/or the at least one generator (which is in the form of a three-phase synchronous machine) for supplying electrical power have/has a rotating field winding composed of HTSL (high-temperature superconductor) wire. Further, each rotating field winding composed of HTSL wire is arranged in a cryostat, which is vacuum-insulated and can be cryogenically cooled by means of the rotating field winding composed of HTSL wire to a temperature between 15 and 77 K.
Without significantly changing the power levels and rotation speed values with pod marine propulsion systems as known from the prior art and the marine propulsion system according to an embodiment of the invention, the ratio between the diameter of the motor housing and the propeller external diameter in the case of the marine propulsion system according to an embodiment of the invention can be reduced to 30%, in comparison to 35 to 40% with the prior art. In comparison to marine propulsion systems which are known from the prior art and which weigh, for example, about 310 t in total, this weight can be reduced to 100 to 200 t by using the marine propulsion system according to an embodiment of the invention.
Furthermore, the efficiency of the electric motor for the marine propulsion system according to an embodiment of the invention can be increased to 99% in comparison to 97.5% in the case of marine propulsion systems as known from the prior art. The considerable reductions in the physical volume and the total weight, which amount to a factor of approximately two or more, lead either to the usable volume in the hull of the vessel being increased, or allow the hull of the vessel to be designed to be smaller for the same usable volume. The machine bases may be designed to be less complex, thus resulting in considerable financial advantages. Since the excitation is produced without any power consumption, the efficiency is better, and the cooling complexity is reduced.
According to one advantageous embodiment of the marine propulsion system according to the invention, the at least one electric motor (which is in the form of a three-phase synchronous machine) and/or the at least one generator (which is in the form of a three-phase synchronous machine) for supplying electrical power have/has an air gap three-phase winding composed of loomed copper conductors, which is arranged in an annular gap between a rotor and a laminated magnetic iron yoke. In the case of this stator air gap winding, no iron teeth are provided as a source of noise, so that the electric motors and the generators run more quietly.
The reduced weight of the rotor makes it possible to considerably reduce the vibration that occurs. The low synchronous reactance results in a very high short-term torque and stalling torque. An air gap of between 5 and 50 mm, which is larger than that with the prior art, is permissible between the rotor and the stator. The assembly process is considerably simplified, since wider tolerances are permissible for shaft bending, twisting due to vessel propeller forces, etc.
It has been found to be particularly advantageous for the HTSL wire of the rotating field winding to be formed from multifilament ribbon conductors Bi2 Ba2 Sr2 Cu3 Ox or Bi2 Ba2 SrCu2 Ox in a silver or silver-alloy matrix, of YBa2 Cu3 Ox as a thin film on steel strip, nickel strip, strip composed of an alloy containing nickel, silver strip or an MgB2 superconductor.
In order to achieve electric motors of the HTSL type with external diameters which are as small as possible, it is expedient for the rotor (which has the rotating field winding composed of HTSL wire) of the at least one electric motor or generator (which is in the form of a three-phase synchronous machine) to have 6 to 12 poles, and preferably 8 poles.
According to one development of the marine propulsion system according to an embodiment of the invention, each cryostat can be supplied with coolant by way of a coolant circuit.
In order to improve the operational reliability of the cooling apparatus, each cryostat can advantageously be supplied with coolant by at least two redundant coolant circuits.
Cold helium or hydrogen gas is expediently provided as the coolant in the coolant circuit between a cold head and a transfer coupling to the cryostat.
Alternatively, the coolant circuit between a cold head and a transfer coupling to the cryostat may be designed on the cryo heatpipe principle, in which case the transfer coupling is then supplied with liquid coolant, such as liquid neon, liquid hydrogen, liquid nitrogen or a liquefied gas mixture, and vaporized coolant is fed back to the cold head.
The cold head of each coolant circuit can be operated in a simple manner by way of a closed-cycle compressed-gas circuit.
The cooling for the compressed-gas circuit for the cold head can once again be provided by way of a central cooling water supply, sea water, or indirectly by way of a heat exchanging device, which is itself thermally connected to outer surfaces of the vessel over which sea water washes.
If the marine propulsion system according to an embodiment of the invention is in the form of a pod propulsion system, with the at least one electric motor, which is in the form of a three-phase synchronous machine and has the rotating field winding composed of HTSL wire, is accommodated in a motor gondola which is arranged outside the vessel hull. The external diameter of the at least one electric motor may be less than 32% of the external diameter of the vessel propeller by virtue of the high power density which can be achieved in this way. This makes it possible to considerably improve the hydraulic efficiency of the pod propulsion system designed according to an embodiment of the invention, in comparison to the prior art.
If the cold head of each coolant circuit is arranged in an azimuth module (which can be rotated) of the pod propulsion system, it is easily accessible, and in which case, furthermore, there is no need for rotating couplings.
Alternatively, the cold head of each coolant circuit may be arranged in a strut module of the pod propulsion system, in which case it is also possible to achieve easy accessibility to the cooling system, in a maintenance-friendly manner.
Furthermore, when appropriate requirements exist, it is possible to arrange the cold head of each coolant circuit in the motor gondola of the pod propulsion system close to the transfer coupling via which coolant can be introduced into the cryostat which holds the rotating field winding composed of HTSL wire.
A further improvement in accessibility and thus in maintenance-friendliness of the cooling apparatus may be achieved. This can be achieved if the compressed-gas circuit is arranged together with the cold head on or within the azimuth module (which can be rotated) of the pod propulsion system.
The operational reliability of the pod propulsion system designed as described above can be increased if the cryostat of the single electric motor which is arranged in the motor gondola of the pod propulsion system can be supplied with coolant by use of two coolant circuits, each of which has an associated cold head. These two coolant circuits, which are designed as described above, are then mutually redundant with respect to the cooling of the cryostat.
If two co-rotating or contra-rotating (counter-rotating) vessel propellers are provided on the motor gondola of the pod propulsion system, each of which is associated with one of two independent electric motors which are arranged in the motor gondola and whose two rotors are arranged in, in each case, one cryostat, it is advantageously possible to achieve greater redundancy for the same volume as that for pod propulsion systems known from the prior art, with the capability for the two vessel propellers to contra-rotate making it possible to achieve better hydrodynamic efficiency.
In order to improve the operational reliability of the two electric motors which are arranged in the motor gondola, it is advantageous for the two cryostats to be connected to in each case one cold head via a respective coolant circuit.
The configuration of the cooling device can be simplified if the two cryostats are connected via a respective coolant circuit to a single cold head, which is shared by them.
Each cold head advantageously has a respective associated compressed-gas circuit.
The compressed-gas circuit may, for example, be cooled down by way of an integrated sea-water cooling circuit.
Alternatively, each compressed-gas circuit may be cooled down by way of an integrated fresh-water circuit, with a gas/water heat exchanger being provided for heat transmission from the compressed-gas circuit to the integrated fresh-water circuit.
The heat dissipation from the integrated fresh-water circuit can be achieved in a simple manner by this circuit having a further heat exchanger, by which it is thermally connected to sea water.
The transfer of the thermal energy from the integrated fresh-water circuit into the surrounding sea water can be achieved in a physically/technically less complex manner and nevertheless very effectively, by arranging the further heat exchanger for the integrated fresh-water circuit close to the wall of the strut module of the pod propulsion system, so that it can be cooled down by way of sea water via this wall.
Furthermore, if appropriate requirements exist, a refinement may be advantageous in which each compressed-gas circuit is equipped with an integrated gas/water heat exchanger, which is itself arranged close to the wall of the strut module of the pod propulsion system, is thermally connected to the latter, and can be cooled via the latter by way of sea water. This allows the amount of heat from the compressed-gas circuit to be emitted directly to the sea water without the interposition of further circuits.
In a further advantageous embodiment of the marine propulsion system according to an embodiment of the invention, the cold head or heads is or are arranged in the strut module, and the compressed-gas circuit or circuits is or are arranged in or on the azimuth module (which can be rotated) of the pod propulsion system.
Alternatively, the cold head or heads may be arranged in the motor gondola of the pod propulsion system close to the transfer coupling or couplings and the compressed-gas circuit or circuits is or are arranged in or on the azimuth module (which can be rotated) of the pod propulsion system.
Instead of the marine propulsion system according to an embodiment of the invention being in the form of a pod propulsion system, it is also possible for the at least one electric motor, which is in the form of a three-phase synchronous machine and has the rotating field winding composed of HTSL wire, to be accommodated in a propeller shaft pipe on one deck of the vessel.
Furthermore, the at least one electric motor, which is in the form of a three-phase synchronous machine and has the rotating field winding composed of HTSL wire, may be arranged as an in-board motor, by which the vessel propeller associated with it is driven via a shaft system.
The electrical power supply for the marine propulsion system can advantageously be formed by a drive machine and a generator, whose cryostat, which holds its rotating field winding, together with the cryostat of the electric motor can be supplied with coolant by use of a coolant circuit which is shared by the two cryostats.
In order to improve the operational reliability of the marine propulsion system, it is expedient to be possible to supply the cryostat for the generator, together with the cryostat for the electric motor, with coolant by way of two mutually redundant cooling circuits which are shared by the two cryostats.
In order to provide a coolant supply by the force of gravity in a simple manner, it is expedient for the cold head of each coolant circuit to be arranged in the vertical direction above that cryostat which is arranged at the highest point in the vertical direction and is supplied from this coolant circuit.
According to a further advantageous embodiment of the invention, each electric motor, which has its own coolant supply, in the motor gondola of the pod propulsion system is provided with its own electrical power supply.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantages, features and details of the invention will become evident from the description of illustrated embodiments given hereinbelow and the accompanying drawings, which are given by way of illustration only and thus are not limitative of the present invention, wherein:
FIG. 1 shows a cross-section illustration of a first embodiment of a marine propulsion system according to the invention in the form of a pod propulsion system;
FIG. 2 shows a longitudinal section illustration of a second embodiment of the marine propulsion system according to the invention in the form of a pod propulsion system;
FIG. 3 shows a longitudinal section illustration of a third embodiment of the marine propulsion system according to the invention in the form of a pod propulsion system;
FIG. 4 shows a longitudinal section illustration of a fourth embodiment of the marine propulsion system according to the invention in the form of a pod propulsion system;
FIG. 5 shows a longitudinal section illustration of a fifth embodiment of the marine propulsion system according to the invention in the form of a pod propulsion system;
FIG. 6 shows a longitudinal section illustration of a sixth embodiment of the marine propulsion system according to the invention in the form of a pod propulsion system;
FIG. 7 shows a cross-section illustration of the sixth embodiment, as shown in FIG. 6 , of the marine propulsion system according to the invention in the form of a pod propulsion system;
FIG. 8 shows a longitudinal section illustration of a marine propulsion system according to the invention arranged in a propeller shaft pipe at the stern of the ship;
FIG. 9 shows a longitudinal view of a further embodiment of the marine propulsion system according to the invention arranged in the propeller shaft pipe at the stern of the ship;
FIG. 10 shows a longitudinal view of a marine propulsion system according to the invention, equipped with an in-board motor.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A first embodiment (which is illustrated in the form of a cross section in FIG. 1 ) of a marine propulsion system according to the invention in the form of a pod propulsion system 1 has a motor gondola 2 which is arranged underneath the hull 3 of the vessel, and which is illustrated by dashed lines and only partially in FIGS. 1 to 7 .
Within the hull 3 of the vessel, the pod propulsion system 1 has an azimuth module 4 , which is firmly connected to the motor gondola by way of a strut module 5 through the hull 3 of the vessel.
The pod propulsion system 1 can be rotated about a vertical axis with respect to the hull 3 of the vessel, as can be seen from the circular arrows 6 in FIGS. 2 to 6 .
The pod propulsion system 1 as shown in FIG. 1 has an electric motor 7 arranged within the motor gondola 2 . A vessel propeller 8 , which is arranged at the rear end of the motor gondola 2 such that it can rotate, is driven by means of this electric motor 7 .
For this purpose, the electric motor 7 (which is in the form of a three-phase synchronous machine) has an 8-pole rotor 9 , which is equipped with a rotating field winding 10 composed of HTSL (high-temperature superconductor) wire.
This HTSL wire may be formed from multifilament ribbon conductors Bi2 Ba2 Sr2 Cu3 Ox or Bi2 Ba2 Sr Cu2 Ox in a silver or silver-alloy matrix, of YBa2 Cu3 Ox as a thin film on steel strip, nickel strip, silver strip or an MgB2 superconductor.
The electric motor 7 (which is in the form of a three-phase synchronous machine) furthermore has an air gap three-phase or stator winding 11 composed of loomed copper conductors, which is arranged in an annular gap 12 between the 8-pole rotor 9 (which is equipped with the rotating field winding 10 composed of HTSL wire) and a laminated magnetic iron yoke 13 .
The 8-pole rotor 9 which has the rotating field winding 10 composed of HTSL wire is held within a cryostat 14 , which is designed to be vacuum-insulated and can be cryogenically cooled by means of the rotating field winding 10 composed of HTSL wire to a temperature between 15 and 77 K.
The cryostat 14 is included in a coolant circuit 16 via a transfer coupling 15 which is arranged coaxially with respect to the longitudinal center axis of the 8-pole rotor 9 . A cold head 17 is integrated in the coolant circuit 16 and is cooled on the basis of the Gifford-MacMahon, Stirling or Pulsetube principle by means of a compressed-gas circuit 18 , which includes a compressor 19 and a gas/water heat exchanger or cooler 20 .
The coolant circuit 16 , which is provided by the cold head 17 on the one hand and the rotor-side or cryostat-side transfer coupling 15 on the other hand, may carry cold helium or hydrogen gas as the coolant. Furthermore, the coolant circuit 16 may be designed on the cryo heatpipe principle, in which case it is then supplied as the liquid coolant with liquid neon, liquid hydrogen, liquid nitrogen or a liquefied gas mixture to the cryostat 14 and to the transfer coupling 15 , and feeds back vaporized neon, vaporized hydrogen, vaporized nitrogen or a vaporized gas mixture from the cryostat 14 and from the transfer coupling 15 to the cold head 17 .
The compressed-gas circuit 18 including the cold head 17 is, in the exemplary embodiment illustrated in FIG. 1 , accommodated in an easily accessible manner on or within the azimuth module 4 (which can be rotated) of the pod propulsion system 1 , so that there is no need for rotary couplings.
An embodiment of the pod propulsion system 1 , shown in the form of a longitudinal section in FIG. 2 , has two mutually independent electric motors 21 , 22 , by which two vessel propellers 23 , 24 are driven, which are mounted such that they can rotate at the front end and rear end of the motor gondola 2 . The vessel propellers 23 , 24 may be oriented such that they contra-rotate. FIG. 2 also shows the two three-phase supply lines 25 , 26 for the two electric motors 21 , 22 . Each electric motor 21 , 22 has a separate cryostat 27 , 28 . Each cryostat 27 , 28 is connected via transfer couplings 15 to a coolant circuit 29 , 30 , with a respective cold head 31 or 32 being arranged in the respective coolant circuit 29 or 30 . Each respective cold head 31 or 32 is in turn associated with a respective compressed-gas circuit 33 or 34 .
The two compressed-gas circuits 33 , 34 are arranged in the azimuth module 4 , and the two cold heads 31 , 32 are arranged in the strut module 5 of the pod propulsion system 1 , so that they are easily accessible and are maintenance-friendly. The provision of two electric motors 21 , 22 whose 8-pole rotors 9 are supplied with coolant independently of one another results in better availability of the pod propulsion system 1 in comparison to the embodiment shown in FIG. 1 .
The availability can be increased if the electrical power supply for each electric motor 21 , 22 is provided individually via respectively separate sliprings or converters. FIG. 2 shows only a single converter supply, which supplies both electric motors 21 , 22 at the same time.
FIG. 3 shows a modified form of the pod propulsion system 1 as shown in FIG. 2 , in the form of a longitudinal section, in which the cryostats 27 , 28 of the two electric motors 21 , 22 are supplied with coolant by way of the two coolant circuits 29 , 30 . The two coolant circuits 29 , 30 are however, in contrast to FIG. 2 , connected to a cold head 35 which is shared by them and is arranged close to the two transfer couplings 15 of the cryostats 27 , 29 in the motor gondola 2 of the pod propulsion system 1 .
The cold head 35 is itself cooled by a compressed-gas circuit 36 , whose major components are arranged in or fitted to the azimuth module 4 of the pod propulsion system 1 .
The compressed-gas circuit 36 is cooled by use of an integrated sea-water cooling circuit 37 , which extracts thermal energy from the compressed-gas circuit 36 via a heat exchanger unit 38 . The major components of the integrated sea-water cooling circuit 37 are also arranged in or on the azimuth module 4 of the pod propulsion system 1 .
The components which are provided for supplying coolant circuits 29 , 30 which are associated with the cryostats 27 , 28 may also be designed in redundant or duplicated form in order to improve the operational reliability, as shown in the embodiment in FIG. 3 .
In the case of the embodiment of the pod propulsion system 1 shown in FIG. 4 , the cold head 35 is also arranged in the motor gondola 2 , close to the transfer couplings 15 which are arranged coaxially with respect to the rotor axis 39 of the rotors 9 of the two electric motors 21 , 22 . The compressed-gas circuit 36 , which is associated with the cold head 35 , is cooled down by means of a gas/water heat exchanger 40 , which is arranged in the compressed-gas circuit 36 and is also a component of an integrated fresh-water circuit 41 .
The integrated fresh-water circuit 41 is cooled by way of a further heat exchanger 42 , which is thermally connected to the wall 43 of the strut module 5 of the pod propulsion system 1 . The further heat exchanger 42 in the integrated fresh-water circuit 41 is thus cooled down by use of sea water through the wall 43 of the strut module 5 of the pod propulsion system 1 .
The major components both of the compressed-gas circuit 36 and of the integrated fresh-water circuit 41 are arranged in a maintenance-friendly manner in the azimuth module 4 of the pod propulsion system 1 , while in contrast the cold head 35 is, as already mentioned above, seated in the motor gondola 2 of the pod propulsion system 1 .
Alternatively, two cold heads 35 may be provided, each of which is associated with a respective one of the two electric motors 21 , 22 , and both of which may be cooled down by way of the compressed-gas circuit 36 .
The pod propulsion system 1 which is shown in FIG. 5 has an electric motor 7 which drives the single vessel propeller 8 of the pod propulsion system 1 , and occupies virtually the entire interior (whose diameter is constant) of the motor gondola 2 of the pod propulsion system 1 . In comparison to the pod propulsion systems equipped with two electric motors as shown in FIGS. 2 to 4 , in the case of the embodiment shown in FIG. 5 , the length of the motor gondola 2 is made better use of for installation of a higher motor power.
The cryostat 14 of the electric motor 7 is connected by way of the transfer coupling 15 to two coolant circuits 44 , 45 , which are based on the cryo heatpipe principle, and which have a respectively associated cold head 46 and 47 . The two cold heads 46 , 47 are arranged in the azimuth module 4 of the pod propulsion system, and are cooled down by way of compressed-gas circuits 33 , 34 , which are likewise provided in the azimuth module 4 of the pod propulsion system 1 . The redundancy which is provided by the duplicated form of the components which are provided for cooling of the electric motor 7 improves the operational reliability of the pod propulsion system 1 .
In embodiments of the pod propulsion system 1 , illustrated as longitudinal sections and cross sections respectively in FIGS. 6 and 7 , the cryostat 14 of the single electric motor 7 which is arranged in the motor gondola 2 is supplied with coolant from a coolant circuit 16 by the transfer coupling 15 . The cold head 17 , which is associated with the coolant circuit 16 , is arranged in the strut module 5 in the case of the embodiment shown in FIG. 6 , and is arranged in the azimuth module 4 of the pod propulsion system 1 in the case of the embodiment shown in FIG. 7 . In both embodiments, the cold head 17 is cooled down by means of a compressed-gas circuit 18 , with an integrated gas/water heat exchanger 48 being used to extract heat from this compressed-gas circuit 18 . This gas/water heat exchanger 48 is arranged on the wall 43 of the strut module 5 , as can be seen in particular in FIG. 7 .
This gas/water heat exchanger 48 is thermally connected in a corresponding manner to the wall 43 of the strut module 5 , and thus to the sea water surrounding the strut module 5 . In the embodiments shown in FIG. 6 and FIG. 7 , the compressed-gas circuit is cooled down directly by the sea water, in which case the heat exchanger pipe runs 49 in the gas/water heat exchanger 48 can be arranged directly against the wall 43 of the strut module 5 .
In the embodiments shown in FIGS. 8 and 9 , an electric motor 7 for the marine propulsion system is arranged fixed in a propeller shaft pipe 51 , which is formed at the stern 50 of the vessel. The cryostat 14 of the electric motor 7 is connected by way of the transfer coupling 15 to two coolant circuits 44 , 45 , which have a respective cold head 46 , 47 . The two cold heads 46 , 47 are respectively cooled down by a compressed-gas circuit 33 , 34 . The cooling of the cryostat 14 of the electric motor 7 is thus redundant.
In addition to the electric motor 7 for the marine propulsion system, FIG. 9 also shows a power generating system with a generator 52 , which is driven by a drive machine in the form of an internal combustion engine 53 .
The generator 52 has a rotor, which is not illustrated in detail in the figures, with a rotating field winding composed of HTSL wire, with the cryostat for the generator 52 being supplied with coolant in a redundant manner both by the coolant circuit 44 and by the coolant circuit 45 , as can be seen in FIG. 9 . Alternatively, it is possible to supply the generator 52 and the electric motor 7 by way of a single coolant circuit and the associated system parts.
The cold heads 46 , 47 which are shown in FIG. 9 are arranged on a higher deck than the load that is arranged at the highest point, so that the coolant can be supplied by the force of gravity via the coolant circuits 44 , 45 , which are designed on the basis of the cryo heatpipe principle.
Alternatively, the coolant circuits 44 , 45 may also be in the form of separate liquid and cold-gas lines.
In the embodiment of the marine propulsion system according to the invention as illustrated in FIG. 10 , the electric motor 7 is in the form of an in-board motor, on the output side driving a shaft system 54 , which itself rotates the vessel propeller 8 .
An internal combustion engine 53 is provided as the drive machine for the marine propulsion system, drives the generator 52 , and may be in the form of a diesel engine, a gas turbine or a steam turbine.
The generator 52 and the electric motor 7 each have a rotor with a rotating field winding composed of HTSL wire. The two cryostats of the generator 52 and of the electric motor 7 are supplied with coolant by way of a coolant circuit 16 , with the cold head 17 in the coolant circuit 16 being cooled down by way of the compressed-gas circuit 18 . The cold head 17 is arranged above the highest coolant load, so that—as in the case of the embodiment shown in FIG. 9 —the coolant can be supplied by the force of gravity.
According to one exemplary embodiment of a pod propulsion system, a drive stage (equipped with two electric motors of the HTSL type) for a pod propulsion system 1 has a rating of 20 MW at 130 rpm. The available rotation speed range is between 70 and 160 rpm. The external diameter of the vessel propeller is 6250 mm. The external diameter of the motor housing and of the motor gondola of the pod propulsion system is 30% of the external diameter of the vessel propeller. The overall length of the pod propulsion system is approximately 11 000 mm. The vessel propeller torque is approximately 1480 kNm. The weight of the entire system is approximately 100 to 200 t, with the efficiency of the motor stage being approximately 99%.
Exemplary embodiments being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the present invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
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A boat propulsion system includes at least one propeller, at least one electric motor by which the at least one propeller can be driven, and one converter-fed power supply unit. The at least one electric motor can be supplied with electric power by the power supply unit which includes at least one prime mover and at least one generator powered by the prime mover. The at least one electric motor and the at least one generator of the power supply unit may be embodied as three-phase synchronous machines. In order to reduce the volume and weight of such a boat propulsion system while increasing its effectiveness, at least one of the electric motor and the at least one generator configured as a three-phase synchronous machine, includes a rotating excitation coil made of high-temperature super conductor wire. Each rotating excitation coil made of high-temperature super conductor wire is arranged in a vacuum-tight, insulated cryostat by which the rotating excitation coil made of high-temperature super conductor wire can be chilled to a temperature of 15 to 77 K.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to valves, and more particularly to fast acting valves capable of operation under cryogenic conditions.
2. Description of the Prior Art
Valves generally control the flow of material from one place to another, and often provide a seal which restrains the flow of material entirely. Valves are needed which operate under a variety of pressure and temperature oonditions, including cryogenic environments.
In many applications, a valve is needed which opens and closes very rapidly and changes state many times during its useful life. The ability of a valve to meet these requirements may depend upon the number of moving parts in the valve, the manner in which the parts move, the stroke of the actuating mechanism required to change the state of the valve, and the manner in which a particular state of closure is maintained.
Generally, it is preferable for a valve to have a minimum number of moving parts for improved reliability, low cost and long useful life. The manner in which the parts move may be important because under certain temperature and pressure conditions, parts which slide over each other may stick together. Valves which operate in relatively clean environments present additional problems and are particularly susceptible to sticking when parts of the valve rub over each other. Valves having parts which press together without sliding over each other are less likely to stick together in use, and are therefore more reliable.
The valve of the present invention has many uses, and finds particular application in connection with cryogenic pumps operating at very low temperatures and pressures. For such application, it is necessary that impurities in the valve and impurities on the surface of the valve material not contaminate the environment. As all materials will be contaminated initially, it is desirable that it be possible to outgas the contaminants before using the valve. This is ordinarily achieved by baking at high temperatures, ruling out the use of such gasket materials as rubber or plastic in the valve. For this reason, metal to metal seals are preferred in the present invention.
It is also desirable in some applications to construct a valve so that it changes state of closure with a relatively small actuating stroke, and maintains a particular state in the absence of an actuating force. Typical applications for such valves include liquid or gas pipes, storage tanks, internal combustion engines and the like. The actuating stroke may be reduced through mechanical means, and a particular state may be maintained through the use of springs and the like. Added parts are often needed to accomplish these purposes, however, which decreases reliability and may require parts which slide over each other. Thus, there is a need for valves which change state with a relatively small actuating stroke and maintain a particular state in the absence of an external actuating force, with parts which generally press together, without substantial sliding.
Accordingly, one aspect of this invention is to provide a new and improved valve.
Another aspect of this invention is to provide a new and improved fast acting valve which maintains a particular state in the absence of an actuating force, having parts which generally press together without substantial sliding.
Still another aspect is to provide a bow action valve having parts which generally press together withqut sliding, as for use in cryogenic applications.
SUMMARY OF THE INVENTION
In keeping with one aspect of this invention, a flow control apparatus for controlling the flow of material has a valve body with at least one orifice and a closure plate for selectively closing the orifice. The closure plate is mounted on the valve body opposite the orifice at two opposite ends, with one end secured at a substantially fixed location on the valve body, and the other end free to move somewhat relative to the fixed end. The free end may be moved in the direction of the fixed end to bow the closure plate and thereby vary the distance between the plate and the orifice to control the flow of material through the orifice. The plate presses against the valve body under proper conditions to seal the orifice and is moved in relation to the valve body without substantial sliding action. The resiliency of the plate causes the valve to maintain a particular state in the absence of an actuating force. The plate may have a high aspect ratio, and the orifices may be elongated so that a relatively small actuating force is required to change the state of the valve.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-mentioned and other features of this invention and the manner of obtaining them will become more apparent, and the invention itself will be best understood by reference to the following detailed description of a preferred embodiment of the invention, particularly when taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a perspective view of a normally closed valve made according to this invention, shown in its closed position, with a portion of the valve broken away;
FIG. 2 is a side cross-sectional view of the valve of FIG. 1 in an open position, taken along line 2--2;
FIG. 3 is a perspective view of a normally open valve made according to this invention, shown in an open position;
FIG. 4 is a side view of the valve of FIG. 3 in its closed position;
FIG. 5 is an enlarged vertical sectional side view of a retainer hook of the valve of FIG. 1, taken along lines 5--5 in FIG. 1; and,
FIG. 6 is an alternate embodiment of the retainer hook of FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The valves of this invention rely on the resiliency of a metal plate when bent either to close or to open the valves in the absence of an external force. FIG. 1 shows a normally closed valve 12 which selectively permits or restrains the flow of a gaseous, liquid or other material by forming at least a partial barrier to the natural flow of the material. The valve 12 includes a valve body 14, which may be a housing or the like, having a curved face 16 which is generally convex with respect to the valve body 14, and transverse to the direction of natural flow of the material. At least one orifice 18 is provided through which the material may pass. The orifice or orifices 18 may be any suitable number, size and shape, including the plurality of orifices 18 having the elongated shape shown in FIG. 1.
The valve body 14 may be of cast aluminum or any other suitable material. If the material and method of manufacture are selected properly, milling and other additional processing may not be needed after manufacture. The valve body 14 may be installed in a pipe or duct, a tank or other storage device, or the like.
A resilient closure plate 20 is flexibly mounted to the valve body 14 in at least two opposing places. The plate 20 may be of any suitable material which is capable of bowing in the environment in which it operates, without failing due to brittleness, softening or fatigue. The material of the plate 20 must also present a substantially impervious surface to the material being controlled by the valve 12, unless an additional element is secured to the plate 20 for that purpose. The plate 20 thus presents an impervious surface across each of the orifices 18, and may have a plurality of open spaces 34 between and spaced from the orifices 18.
Retainer hooks 22 restrain the plate 20 at an end 11 in substantially fixed pivotal relation to the orifices 18, and retainer hooks 24 restrain the plate 20 at an opposing end 13 providing limited freedom for the plate to bow away from the valve body 14. The retainer hooks 22 may be any suitable device or means which maintains the end 11 at a fixed location on the valve body 14, including the configuration shown in FIG. 1, and may also be a suitable welded or bolted fastening.
The plate 20 is bent over the curved face 16 and is shaped to close the orifices 18. The plate 20 is restrained by the hooks 22, 24 in a manner which puts a spring tension on the plate 20 to seal the orifices 18 when no bowing force is applied at the end 13. A plurality of slots 36 are provided so that the top end 13 of the plate 20 may be pushed generally downward by a bowing means 28, causing the plate 20 to bow away from the orifices 18.
The retainer hooks 24 may be any of a number of configurations which permit the top end 13 of the plate 20 to move generally downward as shown in FIG. 1 under the action of the bowing means 28 and move generally upward under the spring action of the closure plate 20 when the force of the bowing means 28 is released. The hooks 24 hold the upper end 13 of the plate 20 against the valve body 14 so that the plate 20 seals the orifices 18. A straight leg hook 51 shown in FIG. 5 may be used, provided that the leg 51 is adjusted at the proper angle with respect to the curved face 16. An alternative embodiment of the retainer hook 24, shown in FIG. 6, may also be used. The retainer hook 24 (FIG. 6) includes a bent leg 53 which creates a channel 55 between the bent leg 53 and the curved face 16. Adjustment of the bent leg 53 may be less critical than the adjustment of the straight leg 51 because the plate 20 may slide in the channel 55. A gap 57 between the plate 20 and the bent leg 53 will not affect the operation of the valve 12, but will permit slight thermal changes in the size of the valve components, without interfering with valve performance. It also assures that the longitudinal bowing forces at the end 13 be relieved.
The shape of the curved face 16 assures that the plate 20 bows when an appropriate force is applied to it by the bowing means 28. The bowing means 28 may include any suitable apparatus, including a flexible connecting means 30 and an air cylinder 32, as shown in FIG. 1. In the alternative, the bowing force may be a mechanical, hydraulic, or other suitable force which is strong enough to bow the plate 20 as required. The bowing means 28 may push the plate along a line which is generally tangent to the curved face 16, or along any other suitable line which tends to bow the plate 20 away from the valve body 14, rather than slide along it.
The curved face 16 may be any suitable shape relative to the relaxed shape of the plate 20 so that, when the plate 20 is not bowed by the bowing means 28, the hooks 24 assure that a minimum seating pressure is applied by the closure plate 20 at a seating surface 26 which surrounds each of the orifices 18. The seating surface 26 conforms to the shape of the closure plate 20 in the closed position to form a seal with the portion of the plate 20 which is pressed against it.
When a bowing force is not applied, the plate 20 seals the orifices 18, closing the valve 12. One side of the plate 20 will generally be subjected to greater pressure from the material which is restrained than the other side. If the greater pressure is applied against the inside 38 of the plate 20, the resilient force stored in the plate 20 must be sufficient to overcome the material force and seal the orifices 18. If the material force is applied against the outside 40 of the plate 20, less resilient force in the plate 20 may be required.
The valve 12 is normally closed by the resilient energy of the plate 20, with the plate 20 pressed against the curved face 16. When a sufficient force is applied to the plate 20 by the bowing means 28, the plate 20 bows outward, as in FIG. 2, and creates a space 42 between the curved face 16 and the plate 20. The orifices 18 are exposed, permitting material to flow through the valve 12. The plate 20 is lifted substantially from the curved face 16, without sliding substantially across seating surfaces 26 or other portions of the valve body 14. The bowing force may be applied with a component generally away from the valve body 14, or generally downward, so that the plate 20 is lifted away from the plate 20 in the vicinity of the hooks 24. In this manner, sliding action is reduced to a minimum, and the possibility of the plate 20 being stuck to the valve body 14 is greatly reduced.
The plate 20 should be lifted enough so that the orifices 18 are appropriately exposed for the free flow of material. The space 42 between the plate 20 and the orifices 18 at full open should be at least about one half of the aperture width across the center 16a of the face 16, so that the total area of the spaces 42 adjacent each orifice 18 approximates the area of the respective orifice 18 itself. The open spaces 34 should be large enough so that the flow of material through the orifices 18 is not substantially inhibited. The plate 20 may be lifted less if it is desired to vary the flow of material without fully opening the valve 12.
The valve 12 may be designed so that the drive stroke of the bowing means 28 fully opens the valve 12 with a relatively short stroke, to decrease the response time of the valve. In a proposed design, a plate movement of about 0.78 inch adjacent the bowing means 28 causes a maximum separation of about 1.38 inch in the space 42 between the plate 20 and the curved face 16. The valve body 14 has a height of about 20 inches, and the parabolic shape of the curved face 16 produces about a 1.38 inch maximum initial deflection or bias in the plate 20. The width of the orifices 18 is 1.9 inch.
A normally open valve 112 is shown in FIGS. 3 and 4. The valve 112 is similar to the valve 12 of FIGS. 1 and 2, except that a plate 120 is secured to a valve body 114 so that a space 142 is created between the plate 120 and a curved face 116 when endwise force is reduced. The valve 112 is closed by impressing a bowing force on the plate 120 through a bowing means 128, forcing the plate 120 to bow and press against the curved face 116.
The valve body 114 has at least one orifice 118 in the curved face 116. The curved face 116 is shaped generally concave with respect to the valve body 114. One end 111 of the resilient plate 120 is secured in a generally fixed pivotal relation to the valve body 114 by a plurality of retainer hooks 122, and the opposing end 113 of the plate 120 is restrained by a plurality of retainer hooks 124. The retainer hooks 122 may be any suitable shape. The retainer hooks 124 may also be any suitable shape, provided that they retain the plate 120 in the open state shown in FIG. 3, and the closed state shown in FIG. 4. A plurality of slots 136 are provided for the hooks 124 so that the plate 120 may be pushed generally downward by the bowing means 128, causing the plate 120 to bow toward the orifices 118 in the curved face 116, as in FIG. 4. The plate 120 should be secured so that it has at least a slight bow toward the curved face 116 in the normally open position so that the plate 120 bows properly when an external force is applied by the bowing means 128. Many of the design considerations of the valve 112 are similar to those of the valve 12.
The many advantages of this invention are now apparent. The possibility of sticking is greatly reduced because the parts of the valve press together, without substantial sliding. The shape of the curved face provides at least a minimum force at the seating surfaces of the valve, and no external force is required to maintain the valve in its normal state. The valve is fast acting, requiring a relatively short drive stroke to change state, and has very few moving parts, for long useful life.
It is, of course, understood that although preferred embodiments of the present invention have been illustrated and described herein, various modifications thereof will be apparent to those of ordinary skill in the art and, accordingly, the scope of the present invention should be defined only by the appended claims and equivalents thereof. For example, the mating surfaces between the closure plate and the valve body may be any suitable shapes as provide sealing therebetween when the closure plate is bowed or relaxed, as the case may be. Such surfaces may be on appendages to the closure plate and/or the valve body. The retainer hooks could be any configuration which provides the forces needed to hold the plate in place as required, and could be secured directly to the valve body or indirectly by way of adjacent apparatus. Also, the bowing force applied to the plate need not be in the precise direction shown, and could include components in various directions, provided that a suitable component is provided in the direction of the secured edge. A preferred direction is directly toward the secured end.
Various features of the invention are set forth in the following claims.
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A bow action valve for controlling the flow of material includes a valve body having at least one orifice and a closure plate. The closure plate is secured in front of the valve body at two opposite ends, with one end secured at a substantially fixed location on the valve body, and the other end free to move toward and away from the fixed end. The free end may be moved with a component of motion in the direction of the fixed end to bow the plate means and thereby vary the distance between the plate and the orifice to control the flow of material through the valve body.
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This application is a national phase application of PCT/KR2006/002872, and claims priority from Korean application (KR) 20-2005-0022608 (Aug. 2, 2005) for inventor KIM, Ki Ryong.
TECHNICAL FIELD
The present invention relates to a road traffic-control signboard assembly, and more particularly, to a road traffic-control signboard assembly having an automatic returns function.
BACKGROUND ART
Road traffic-control signboards are essential elements in running of vehicles. Since road traffic-control signboards should be optimally recognized at drivers' visual fields, they are usually fixed at right angle to vertical supports which are built vertically at the margin of roads. For example, a conventional road traffic-control signboard assembly will be described below with reference to part of FIG. 1 .
In the case of the conventional road traffic-control signboard assembly, a road traffic-control signboard 40 is simply fixed to the road traffic-control signboard stay bar 1 which is extended again over the road, using a U-bolt and nut. Therefore, assemblers' manpower can be reduced but the durability thereof is very poor. The following problems are caused. That is, as stated above, the conventional road traffic-control signboard assembly assembles the road traffic-control signboard 40 with the traffic signboard stay bar 1 using the U-bolt and nut. Thus, if strong force is applied to the conventional road traffic-control signboard assembly, because typhoon blows, an initial position of the road traffic-control signboard 40 is changed to thus make the front surface of the road traffic-control signboard 40 turn up to the sky or down to the road, or make it suspended at a slope. As a result, the road traffic-control signboard 40 loses its function and causes a failure in safety running of vehicles.
In the meantime, if impact is applied to the conventional road traffic-control signboard assembly, due to the excessively loaded freight in freight vehicles or the top portion of special-purpose motor vehicles such as cranes or heavy equipment, the obverse of the road traffic-control signboard 40 is slanted heading toward the road or is damaged. Finally, the same problems as those described above are caused. Hereupon, local government road facilities that receive accident or damage reports ride bucket vehicles and go to sites immediately, in order to straighten the road traffic-control signboard whose initial position has been changed again or replace it by a new one. For this reason, roads are blocked to thus delay a smooth road condition and cause a big economical loss and damage nationalistically. On the other hand, when typhoon blows or after typhoon passes a lot of road traffic-control signboards are out of position over the downtown whole area. In this case, big problems such as confusion, discomfort, and traffic jams are caused.
Moreover, repair works of long hours cause various kinds of big problems. Hereupon, to solve the above-described problems, this inventor filed a Utility-model application No. 20-2003-0040773 on Dec. 26, 2003 with the Korean Intellectual Property Office entitled “Horizontal support structure for making traffic-control signboards rotate” which has been registered as a Utility-model registration No. 20-0349900-0000 on Apr. 29, 2004. By the way, the above-described registered conventional art greatly changes the structure of the existing road traffic-control signboard stay bar 1 . In principle, the existing road traffic-control signboard stay bar 1 does not cause any problem but is complicated in the structural viewpoint since a coil spring should be is mounted so as to be concentric with the road traffic-control signboard stay bar 1 . As a result, in the case of the conventional art, it is not so easy to manufacture the road traffic-control signboard 40 and assemble it in the road traffic-control signboard stay bar 1 to thus cause the manufacturing cost to greatly rise up and the maintenance to be difficult and to additionally cause an unsafe problem since the weight of the road traffic-control signboard assembly is heavy.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
To solve the above problems, it is an object of the present invention to provide a road traffic-control signboard assembly having a generally advanced automatic return function using structure of an existing road traffic-control signboard stay bar 1 as it is, which is preeminently improved in view of the function, economy, assembly, maintenance, weight, etc., in comparison with those of the conventional art. To accomplish the above object of the present invention, according to an aspect of the present invention, there is provided a road traffic-control signboard assembly comprising: a tubular elastic body having an insertion groove so as to be inserted into a road traffic-control signboard stay bar which is connected with a vertical support at right angle and a hole into which a rotation preventing screw can be inserted at right angle; a semicircular upper clamp which is assembled to enclose the tubular elastic body at the upper portion of the tubular elastic body, including a tightener having bolt holes through which a respective bolt is penetratively fixed for fixing a below-described lower clamp, in which the tightener is extended from the semicircular upper clamp, a hole into which a rotation preventive screw can be inserted at right angle, and a hasp which can hang a below-described tension spring on the upper portion of the semicircular upper clamp; a flat lower clamp which is hinged with the upper clamp, having bolt holes through which a respective bolt is penetratively fixed for fixing the upper clamp; a support plate which is assembled in a hinged manner with the lower clamp and the upper clamp, to support a road traffic-control signboard; a hinge pin which assembles the upper clamp, the lower clamp and the support plate all in a hinged manner; a reinforcement plate at the upper portion which a hanger for hanging the tension spring, in front of which the road traffic-control signboard is fixed, and with which the support plate is assembled with bolts and nuts; a tension spring which is assembled between the hasp of the upper clamp and the hanger of the reinforcement plate, which supports the road traffic-control signboard so as to return vertically even if the road traffic-control signboard moves; and bolts and nuts which rigidly tighten the upper clamp and the lower clamp. Preferably, a plate-shaped or rod-shaped stopper is additionally fixed on the upper portion of the upper clamp, so that the erect road traffic-control signboard is not inclined toward the upper clamp. Preferably, the material of the tubular elastic body is selected among rubber, sponge, and urethane.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects and advantages of the present invention will become more apparent by describing the preferred embodiments thereof in detail with reference to the accompanying drawings in which:
FIG. 1 is a perspective view showing the whole structure of a road traffic-control signboard assembly according to the present invention; and
FIG. 2 is a sectional view showing a state of use of the road traffic-control signboard assembly according to the present invention.
BEST MODE FOR CARRYING OUT THE INVENTION
Herein below, a road traffic-control signboard assembly according to a preferred embodiment of the present invention will be described. The same reference numeral presented in the drawings show the same element.
First, the road traffic-control signboard assembly according to the present invention does not change structure of an existing road traffic-control signboard stay bar 1 but uses it as it is. In this point of view, the present invention differs greatly from the conventional art. The present invention has many inventive characteristics in which its structure is very simpler and its durability is more excellent than those of the conventional art.
That is, referring to FIGS. 1 and 2 in the present invention, a tubular elastic body 30 made of rubber, sponge, or urethane can be simply inserted into a proper position of a road traffic-control signboard stay bar 1 (hereinafter, referred to as a stay bar 1 ). As shown in FIGS. 1 and 2 , an insertion groove 31 that can be inserted into the outer surface of the stay bar 1 . The lower portion of the tubular elastic body 30 is opened and thus the insertion groove 31 can be extended by hands seizing the tubular elastic body 30 . Then, the tubular elastic body 30 can be simply inserted into the stay bar 1 . Finally, the tubular elastic body 30 is closely fixed to the stay bar 1 as shown in FIG. 2 . In the meantime, the tubular elastic body 30 is preferably fabricated in various forms in size, according to change in diameter of the stay bar 1 , but since the tubular elastic body 30 has an elasticity naturally, there is no reason to produce the tubular elastic body 30 in various sizes certainly because there is no problem to use it even if diameter of the stay bar 1 is a little big or small. Further, since the standard and diameter of the stay bar 1 are substantially the same, only one basic type of the tubular elastic body 30 can be used without causing any problems.
As described above, after the tubular elastic body 30 is inserted into the stay bar 1 , a hole is formed on the stay bar 11 through a hole 32 using a hand drill. The diameter of the hole does not cause any hindrance in intensity of the stay bar 1 . In this case, if the end portion of a rotation preventive screw 16 may be inserted into the hole, the diameter of the hole can be acceptable. Here, the tubular elastic body 30 can be assembled with the stay bar 1 after a hole has been formed on the stay bar 1 .
Next, after a semicircle upper clamp 10 is positioned at the upper portion of the tubular elastic body 30 , the rotation preventive screw 16 is assembled through the hole 32 of the tubular elastic body 30 and a hole 13 of the upper clamp 10 . Accordingly, as shown in FIG. 2 , the tubular elastic body 30 and the upper clamp 10 can be kept in their positions on the stay bar 1 .
Then, a flat lower clamp 20 which is assembled with the upper clamp 10 by a hinge pin 15 in a hinged manner, is made to contact the bottom of the stay bar 1 and to be fixed to the stay bar 1 using bolts 50 and nuts 51 , as shown in FIG. 2 .
Then, a support plate 70 is assembled in a hinged way with the upper clamp 10 and the lower clamp 20 by the hinge pin 15 . Then, a reinforcement plate 60 to which a road traffic-control signboard 40 is fixed, is located in front of the support plate 60 , and is assembled by bolts 41 and nuts 42 . That is, the support plate 70 , the reinforcement plate 60 and the road traffic-control signboard 40 are integrally formed.
As shown in FIGS. 1 and 2 , a tension spring 80 is hung between a hasp 14 of the upper clamp 10 and a hanger 61 of the reinforcement plate 60 , and assembled. As shown in FIG. 2 , a plate-shaped or rod-shaped stopper 90 is additionally fixed on the upper portion of the upper clamp 10 , so that the erect road traffic-control signboard 40 is not inclined toward the upper clamp 10 .
As described above, the rotation preventive screw 16 can be replaced by an ordinary pin, bolt, or annular rod. Here, when the tubular elastic body 30 and the upper clamp 10 are assembled with the stay bar 1 after the annular rod is soldered and fixed to the stay bar 1 beforehand, the annular rod can pass through and protrude from the respective holes 32 and 13 . However, in this case, it is naturally expected that it will be difficult to work. Also, the tubular elastic body 30 of the present invention is cut at its lower portion thereof, and thus the insertion groove 31 is opened. Accordingly, the lower clamp 20 contacts justly the bottom of the stay bar 1 , and thus the road traffic-control signboard 40 can be turned by as a big angle as an arrow trajectory of FIG. 2 . As a result, in the case that impact due to collision of a freight vehicle is applied to the lower portion of the road traffic-control signboard 40 , the road traffic-control signboard 40 is smoothly escaped from the impact lest the central portion of the road traffic-control signboard 40 should not be damaged. As being the case, a perfectly pipe-shaped tubular elastic body can be used. In the meantime, as described above, any commercial changes belong to the technical scope of the present invention.
It is natural that two sets of road traffic-control signboard assemblies according to the present invention be used for one road traffic-control signboard. If the road traffic-control signboard becomes large in size, it is natural that several road traffic-control signboard assemblies be assembled with one stay bar in use.
As described above, the road traffic-control signboard assembly according to the present invention is used in the state of FIG. 2 . Even if wind force or other impact is applied in front of the road traffic-control signboard 40 in the FIG. 2 state, the road traffic-control signboard 40 is pushed to the left-side direction of the arrow and is turned over within various angle ranges. Thereafter, if the wind force that is, birr or other impact disappeared, the road traffic-control signboard 40 returns to the original position by the pulling force of the tension spring 80 . Here, a reason why the road traffic-control signboard 40 has been pushed backward by the birr or impact which has been applied to the road traffic-control signboard 40 is because the stopper 90 is fixed to the upper clamp 10 , and thus the upper portion of the road traffic-control signboard 40 is not pushed backward based on the hinge pin 15 .
In the meantime, even in the case that strong wind blows from the left side of the road traffic-control signboard 40 to the right side thereof, in the FIG. 2 state, the road traffic-control signboard 40 is not turned to the left side of the road traffic-control signboard 40 but is turned only to the right side thereof. This is also because the road traffic-control signboard 40 cannot be turned toward the upper clamp 10 by the stopper 90 . Here, a coil spring is assembled with the hinge pin 1 , to thus keep the road traffic-control signboard 40 in its position. However, it is not always necessary to assemble the coil spring with the hinge pin 1 .
As described above, the present invention provides a road traffic-control signboard assembly having an automatic return function even if impact is applied to a road traffic-control signboard. The conventional art changes the structure of the stay bar 1 , but the present invention does not change the existing stay bar 1 in use. This feature of using the existing stay bar without changing the structure of the stay bar is inventive in itself. Further, the road traffic-control signboard assembly can be simply assembled with and disassembled from the stay bar 1 , and the structure of the road traffic-control signboard assembly is very simple. Accordingly, it is easy to fabricate the road traffic-control signboard assembly. Moreover, the present invention is more excellent in its maintenance, more inexpensive in its manufacturing unit cost, and lighter in its weight to thus enable a very easy installation and maintenance work, than those of the conventional art. As a result, the present invention has an economic efficiency having preeminently improved characteristics.
Further, a semi-permanent use is possible since the present invention has an excellent durability from the structural characteristic and the frequent breakdown has hardly occurred. In particular, the tubular elastic body 30 does not need to be fabricated according to diameter of the stay bar 1 , even if the diameter of the stay bar 1 alters a little, and the road traffic-control signboard assembly according to the present invention can be flexibly used, to thereby provide an effect of doing a big contribution in enhancing the whole economic efficiency, convenience, workability.
As described above, the present invention has been described with respect to particularly preferred embodiments. However, the present invention is not limited to the above embodiments, and it is possible for one who has an ordinary skill in the art to make various modifications and variations, without departing off the spirit of the present invention. Thus, the protective scope of the present invention is not defined within the detailed description thereof but is defined by the claims to be described later and the technical spirit of the present invention.
INDUSTRIAL APPLICABILITY
As described above, the present invention provides a road traffic-control signboard assembly which can be used for a traffic-control signboard.
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Provided is a road traffic-control signboard assembly with which a road traffic-control signboard can be assembled while being linked with a vertical support at right angle. The road traffic-control signboard assembly is fitted with and fixed to a road traffic-control signboard stay bar and has a structure of being returned to an original position even if impact by typhoon or collision of vehicles is applied to the road traffic-control signboard. Thus, the road traffic-control signboard assembly prevents a phenomenon that an initial fixed position of the road traffic-control signboard is changed because of impact by typhoon or collision of vehicles which is applied to the road traffic-control signboard, to thereby lose the function of the road traffic-control signboard.
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CLAIM OF PRIORITY
[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 61/819,373, filed May 3, 2013 and titled “CALIBRATION-FREE CONTINUOUS BIN LEVEL SENSOR” which application is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] This invention generally relates to sensors and sensing systems for measuring material fill levels in containers.
BACKGROUND OF THE INVENTION
[0003] Capacitive sensors are used extensively for level measurement and proximity detection. A conventional capacitive sensor, which includes one or more conductive plates, is sensitive to changes in the dielectric constants of materials or fluids near or surrounding the plates. The capacitive sensor detects the presence or lack of material in the vicinity of the plates by measuring the capacitance between the plates, which is proportional to the dielectric constant of the material filling the space between the plates. By measuring this capacitance, the quantity of material (for level measurement) or the existence of the material (for proximity detection) may be determined. Similarly, another conventional form of capacitive sensor, which uses linear electrodes, e.g., a long wire or strip immersed into a tank or storage bin holding a variable level of fluid or material, measures the level of the fluid or material by sensing and measuring the capacitance of the linear electrodes.
[0004] The accuracy of conventional capacitive sensors is based in large part on the dielectric constant of the material to be sensed. For example, when sensing capacitance, a fifty percent change in relative permittivity (the dielectric constant) causes a corresponding fifty percent change in the measured capacitance, i.e., the relationship is linear. Designing and producing capacitive sensors is therefore hampered by the sensitivity of conventional capacitive sensors to changes in the dielectric constant of the material to be sensed. One continuous capacitive level sensing system is the CLC series offered by SensorTechnics (www.sensortechnics.com) which appears to estimate a fill level of a container based on knowledge of the material being measured. If the material changes, however the sensor may require recalibration.
[0005] In U.S. Pat. No. 6,539,797 to Livingston et al, there appears to be disclosed a two electrode sensor embodiment wherein one is fully immersed and one partially immersed to measure material level independent of the dielectric constant of the material. It appears however that the measurements are processed in a more complex manner and calibration measurements are more numerous than the various embodiments disclosed herein.
[0006] There is a need for fill level sensing devices for containers that are independent of permittivity, easy to use, and require minimal to no calibration.
SUMMARY OF THE INVENTION
[0007] In one example embodiment, a capacitance based level sensor is provided that automatically adjusts for the permittivity of the material being measured, such that it will function equally well for bulk materials such as grain and seed as well as liquids such as fertilizers, pesticides, oil and gasoline. The sensor will function without additional adjustment even if the material being sensed changes, such as a change from corn to soybeans, for example. In related embodiments, dry materials such as salt, sand, dirt, dry fertilizers, pesticides and herbicides are also measurable in containers.
[0008] In this example embodiment, the sensor system or assembly described herein can automatically calibrate itself upon installation into an empty bin, eliminating the need to actually fill the bin to calibrate the level reading. The sensor will provide consistent measurement regardless of material properties (permittivity, density, temperature or moisture content). The capacitive nature of the sensor means that in some circumstances, it will sense the material through plastic/glass/fiber glass thereby allowing the sensor assembly to be mountable on the outside of a bin or container. The same sensor assembly is configurable so as to function with bins or containers of different heights from inches to 10's of feet. The electrodes of the sensor system are designed to provide a continuous level reading.
[0009] Further, the sensor systems described herein circumvent the need to know exactly what type of material is in a container by making a dual capacitance measurement. This has at least three significant advantages over existing sensors: 1) it eliminates the need to calibrate the sensor for the material being measured; 2) it enables the sensor to self-calibrate at empty and full levels, eliminating the need to actually fill the bin with material to calibrate fill levels; and 3) it enables the same electrical hardware to function with electrodes of various lengths, maximizing installation flexibility.
[0010] In a related embodiment, an active shield can be used to protect an externally mounted sensor from being influenced by rain or other weather elements. In related embodiments, the sensor systems described herein are configurable to provide: automatic material calibration, self-calibrating level measurement or measurement of liquid levels.
[0011] In a related embodiment, the need for pre-installation into an empty cell can be eliminated which in turn removes the empty bin self-calibration step. This totally calibration-free sensor mode is accomplished by making each of the two capacitance measurements at two frequencies. This means that the sensor assembly can be installed into a partially filled bin, a significant advantage for retrofit installations.
[0012] In one example embodiment, a single frequency sensor system is provided herein for measuring a fill level of material in a container that is, but is not limited to, a) material independent; b) frequency independent; c) functions with unknown but constant electrode capacitance; d) functions with arbitrary but known electrode lengths; e) only requires a single empty bin calibration measurement during installation; f) is independent of measurement frequency drift; and g) is independent of parasitic capacitance level.
[0013] In another example embodiment, a multi-frequency sensor system for measuring a fill level of material in a container is provided that has the attributes of the single frequency sensor with the exception that it requires no calibration whatsoever as long as the material being measured has a frequency dependent permittivity.
[0014] In another example embodiment, the empty bin calibration constants can be determined from multi-frequency measurements at two distinct bin levels and stored for later use with materials that have frequency independent permittivity, thus necessitating use of a single frequency level determination. The benefit of this approach is that no physical calibration steps are required to find the constants.
[0015] In yet another example embodiment, a multi-frequency method for calculating a level of fluid or material contained within a container or vessel is provided that includes providing a sensing capacitive element configured from two parallel sensing electrodes positioned adjacent the container or vessel such that changes in a material level cause a proportionate change in a first capacitance of the sensing electrodes, wherein said sensing electrodes have a length LL and a nominal capacitance per unit length C 0 , and wherein the capacitance of said sensing capacitive element varies in accordance both with the extent of the immersion of the parallel electrode in the fluid or material and a dielectric constant of the fluid or material. In addition, a reference capacitive element is provided that is configured from two parallel reference electrodes positioned adjacent to a bottom of the container or vessel, the reference electrodes having a length LR and a capacitance per unit length C 0 , wherein the reference electrodes are adapted to be in contact with the material or fluid within the container, and wherein the capacitance of the reference electrodes is a function of the dielectric constant of the fluid or material. Further, a measured capacitance is determined of the sensing capacitive element at a first frequency (f1) and at a second frequency (f2) and a measured capacitance is determined of the reference capacitive element at the first frequency (f1) and at the second frequency (f2). A level of the fluid or material within the container is generated from a product of:
[0016] a ratio of L R (reference electrode length) and L L (sensing electrode length) and a ratio of:
[0017] a. a difference of the measured capacitance of the sensing element at the first frequency and the measured capacitance of the sensing element at the second frequency as a numerator;
[0018] b. a difference of the measured capacitance of the reference element at the first frequency and the measured capacitance of the reference element at the second frequency as a denominator.
[0019] The various embodiments described herein will now be described more fully hereinafter with reference to the accompanying drawings, which are intended to be read in conjunction with both this summary, the detailed description and any preferred and/or particular embodiments specifically discussed or otherwise disclosed. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided by way of illustration only and so that this disclosure will be thorough, complete and will fully convey the full scope of the invention to those skilled in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Other important objects and advantages of the present invention will be apparent from the following detailed description of the invention taken in connection with the accompanying drawings in which;
[0021] FIG. 1 illustrates an example embodiment of a two sensing element system for bin level measurement according to the teachings herein;
[0022] FIG. 2 illustrates in an example embodiment of an active shield for a bin or tank level sensor as taught herein;
[0023] FIG. 3 illustrates a chart of an example bin level measurement of a PVC pipe arrangement using soybean and wheat as taught herein;
[0024] FIG. 4 illustrates a chart of various example bin level measurements using various example sensor arrangements as taught herein;
[0025] FIG. 5 illustrates a schematic a frequency generating circuit and processing means for a multi-frequency sensor as taught herein;
[0026] FIG. 6 illustrates a chart of oil type sunflower seeds and plastic 6 mm air gun pellets using a measured capacitance example sensor arrangement as taught herein.
[0027] FIG. 7 illustrates a chart of the sunflower seeds and air gun pellets of FIG. 6 and an estimated fill level versus an actual level when a permittivity independent method is used as taught herein; and
[0028] FIG. 8 illustrates a photograph of an example bin level measurement apparatus as taught herein.
DETAILED DESCRIPTION OF THE INVENTION
[0029] Following are more detailed descriptions of various related concepts related to, and embodiments of, methods and apparatus according to the present disclosure. It should be appreciated that various aspects of the subject matter introduced above and discussed in greater detail below may be implemented in any of numerous ways, as the subject matter is not limited to any particular manner of implementation. Examples of specific implementations and applications are provided primarily for illustrative purposes.
[0030] Referring now to the Figures, in particular to FIGS. 1 , 2 and 5 , in one example embodiment, a sensor system or assembly 100 for use on a bin or container 10 consists of two sensing elements 110 and 112 , an electronics module 120 and an optional shield material 130 (in this example, a metal tape). A first sensing element 110 is a bin level element, is configured to be long enough to span from a top 12 to a bottom 14 of bin 10 . A second sensing element 112 , the reference element, is for a reference measurement and should preferably be mounted at bottom 14 of bin 10 so that it will normally be fully exposed to the material being measured. In this example embodiment, sensing elements 112 and 114 each consist of a length of jacketed parallel conductors (such as twin lead radio wire).
[0031] In other related embodiments, the sensing elements are mountable internally or, in the case of plastic, glass, or fiberglass bins, the sensing elements or leads or electrodes may be mounted externally. External mounting for outdoor applications suggests that the sensing elements be covered by metal tape, which is driven by electronics module 120 , to serve as an active shield.
[0032] In this example embodiment, electronics module 120 measures the capacitance of the two sensing elements 112 and 114 . The electrodes serving as a relaxation oscillator timing capacitor circuit that operates such that the oscillator frequency is a function of the electrode capacitance. In a related embodiment, a circuit drives the electrodes with a constant frequency and uses the output of an impedance divider or bridge to estimate the capacitance. A schematic diagram of an example embodiment of a frequency generating circuit 500 and processing means for a multi-frequency sensor is shown in FIG. 5 . The reference and bin level sense electrodes are each driven by a Schmitt Trigger based astable oscillator. The frequency of oscillation is inversely proportional to the product of the feedback resistance and the electrode capacitance. The frequency of the oscillators can be controlled by changing the feedback resistance in the Schmitt Trigger which can be accomplished with a processor controller. For the oscillators shown in the schematic,
[0000]
f
(
kHz
)
=
9.5592
·
10
8
R
feedback
(
kOhm
)
·
C
electode
(
pF
)
[0000] where R feedback is the total feedback resistance (the parallel resistance when the frequency select switch is closed). C electode includes capacitance associated with the material in the bin or container plus any constant parasitic capacitance. The frequency select switches decrease the resistance by about a factor of 10 over the open switch resistance which in turn increases the oscillation frequency by a factor of 10. The values shown lead to oscillation frequency of 400 kHz when the switch is open and 4 MHz when the switch is closed when the electrode capacitance is about 20 pF. The processor monitors the frequency of oscillation and can thereby calculate the electrode capacitance. The processor performs the appropriate algebraic steps to determine the bin level and outputs that result in the form of PWM duty cycle, frequency, analog voltage, or digital value.
[0033] In situations where electrodes are mounted on the exterior of the bin, active shielding may be required to prevent unwanted bias in the capacitance measurements by external influences such as rain and nearby material. A partial electric circuit 200 describing the active shielding of sensor system 100 is shown in FIG. 2 . In this example electric circuit 200 , one electrode from each sensing element 112 A (or 114 A (not shown)) is held at electrical ground 210 and the other active electrode 1128 (or 114 B (not shown)) is driven at some frequency by the measurement circuit, which in this example is an oscillator 220 and amplifier combination 230 . Included in the electronics is an amplifier for each active electrode that follows the signal driving that particular active electrode. This signal is applied to a shield tape member 240 that is placed over the sensing electrodes in external bin outdoor mounting applications.
[0034] Referring again to FIG. 1 , in normal operation, bin level sensing element 114 is partially buried (or covered) in some bulk material or partially submerged in a liquid. For FIG. 1 , the following parameters in this example embodiment are defined as follows:
[0035] C 0 is sensing element capacitance per unit length (11.8 pF/m for 300 twin lead)
[0036] L is the length of the sensing element in meters (m)
[0037] R is the length of the reference element in meters
[0038] H is the height of the material in the bin in meters (unknown)
[0039] The bin level can be expressed as a percentage of the total electrode length L:
[0000]
bin
level
=
(
C
tot
-
C
tot
empty
)
(
C
ref
-
C
ref
empty
)
·
R
L
·
100
%
[0000] C tot is the total capacitance of the bin level sensing element (measured)
[0040] C ref is the total capacitance of the reference sensing element (measured)
[0041] C tot empty is the capacitance of the bin level sensing element when the bin is completely empty (measured during installation)
[0042] C ref empty is the capacitance of the reference sensing element when the bin is completely empty (measured during installation)
[0043] Significant in this expression for calculating or measuring the bin level is that all of the physical parameters are eliminated: 1) the bin sensing element length L can be arbitrary from installation to installation; 2) the reference sensing element length R can be arbitrary; 3) the nominal capacitance of the sensing elements C 0 can be unknown; and 4) the material permittivity ∈′ can be unknown. The fact that the material permittivity can be unknown further implies that: a) the material density can be unknown; b) the material temperature can be unknown; c) the material moisture level can be unknown; and d) the measurement frequency can be unknown.
[0044] In various embodiments, some of the sensor systems described herein are configured to determine the bin level as long as an empty bin measurement of the capacitance is made of the two sensing elements during sensor installation. The empty measurements can be made without any material in the bin, but this only needs be done once. In normal operation, the reference sensing element is assumed to be fully exposed to the material in the bin, meaning it is best mounted at the bottom of the bin. The electrical measurements used to determine bin level can easily be biased by parasitic contributions to capacitance. Hence, additions to the overall capacitance measurement due to wiring, circuitry, installation, etc., are not influenced by the permittivity of the material in the bin. The various measurement methods developed for bin level minimize the parasitic contributions through the differences of the measured capacitance in the numerator and denominator, effectively canceling out parasitic contributions to the measurement.
[0045] In a related embodiment, the need for calibration measurements of any type (including the empty bin measurement during installation) can be eliminated entirely, making this a calibration free sensor. This is accomplished by making capacitance measurements of the level sensing and reference electrodes at two frequencies, nominally about 100 kHz and about 1 MHz, resulting in the following expression for the bin level:
[0000]
bin
level
=
(
C
tot
f
1
-
C
tot
f
2
)
(
C
ref
f
1
-
C
ref
f
2
)
·
R
L
·
100
%
[0046] C tot f1 is the measured capacitance of the bin level sensing element taken at frequency f1
[0047] C tot f2 is the measured capacitance of the bin level sensing element taken at frequency f2
[0048] C ref f1 is the measured capacitance of the reference level sensing element taken at frequency f1
[0049] C ref f2 is the measured capacitance of the reference level sensing element taken at frequency f2
[0050] All four measurements are taken at the time of the level measurement meaning there is no separate set of calibration measurements. Furthermore, all of the properties of the single frequency bin level method (and mathematical expression) remain intact: 1) the level sensor requires no calibration; 2) the level sensor is material independent, requiring no knowledge of material permittivity; 3) the level sensor is frequency independent, requiring no knowledge of the measurement frequencies which in turn means that the frequencies can drift over time without affecting the level measurement; 4) no knowledge of the electrode capacitance C 0 is required, the only requirement being that the capacitance per unit length be constant; and 5) the electrode lengths R and L can be arbitrary in size but their values must be known.
[0051] Substantially accurate application of the two frequency bin level method as taught herein depends on the permittivity of the sensed material varying with frequency. This generally is not a problem for hygroscopic materials such as grain but for some materials, like glass, this will present a challenge. For constant permittivity materials, it is preferable to utilize one of the single frequency methods as taught herein for bin level with its requirement of a single empty bin calibration measurement.
[0052] The need for calibration can also be eliminated for the single frequency constant permittivity scenario if the multi-frequency approach can first be applied to material that has frequency dependent permittivity. In this case, the empty container calibration constants C tot empty and C ref empty can be determined algebraically from bin level measurements computed using the multi-frequency method. These levels, H1/L and H2/L can then be combined with the capacitance measurements at the two levels to determine the empty container capacitance values as follows:
[0000]
C
ref
empty
=
(
C
tot
@
H
1
-
c
tot
@
H
2
)
-
H
1
R
·
C
ref
@
H
1
+
H
2
R
·
C
ref
@
H
2
(
H
2
-
H
1
R
)
C
tot
empty
=
C
tot
@
H
1
+
H
1
R
(
C
ref
empty
-
C
ref
@
H
1
)
[0053] In both expressions, the ‘@H1’ and ‘@H2’ refer to previously defined capacitance measurements C tot and C ref made at fill levels H1 and H2 respectively. The levels will preferably differ from one another by about 10% to about 25%. The frequencies of measurement for each fill level are not required to be the same.
[0054] The benefits of using two frequencies to determine the single frequency calibration constants are that it is not necessary to perform a physical calibration measurement and the resulting calibration constants can be updated continuously, thus accounting for shifts in parasitic capacitance. When constant permittivity material is encountered, the sensor assembly can automatically shift to a single frequency calculation using the most recent calibration values. During single frequency operation, the calibration values cannot be updated.
[0055] Referring now to FIG. 3 there is illustrated a graph 300 of data gathered of an example bin level measurement of a PVC pipe arrangement using soybean and wheat as taught herein. The sensor system was also tested on salt. The grain level test consisted of taping the twin lead to the outside of a 34 inch long and one inch diameter PVC (plastic) pipe. The pipe was filled with either soybean or wheat grain and the effect of the capacitance change on an oscillator frequency was recorded, with the oscillator frequencies ranging from about 97 KHz to about 100.5 KHz. The plot shows the performance of sensor assembly 100 on both wheat and soybeans. The horizontal axis is approximately 10ths of an inch of grain height. In this example embodiment, the grain level was sensed through the plastic pipe; hence a sensor attached to the outside (or inside) of a plastic grain tank is operative. As shown, the different grains have different slopes on the curves. Because this is a capacitance sensor, different materials will read differently, but the bin level calculation will still be “measured material” independent. Further, the moisture level of a fill material may normally affect the reading, however the permittivity independence of the sensor assembly taught herein means this should not affect the bin level measurement.
[0056] Referring now to FIG. 4 there is illustrated a graph 400 of various example bin level measurements using various example sensor arrangements as taught herein. In these example embodiments, a Clapp oscillator with a 300 ohm twin lead was used. Frequency (vertical axis) was plotted against the container height (in inches—horizontal axis) for: 1) an aluminum cylinder; 2) inside a plastic bucket: 3) 2 revolutions around the outside of the container; 4) and electrodes located on both walls of a container. In one embodiment, the twin lead was wrapped around a bucket containing salt and the sensor was able to detect the salt level. In another related embodiment, the sensor was attached to the support structure inside a tank and the level reading was still generated. In these example embodiments, the oscillator frequencies ranged from about 4.47 MHz to about 4.54 MHz.
[0057] Referring now to FIGS. 6-8 , there are shown data plots for oil-type sunflower seeds versus airgun pellets using an apparatus shown in FIG. 8 according to the teachings herein. In particular, FIG. 8 illustrates a photograph of an example bin level measurement apparatus used to make capacitance measurements as the material level is varied in a 36″ long acrylic tube with a 0.1″ wall thickness. The electrodes, consisting of 300 Ohm twinlead transmission line, are attached to the outside of the tube. This “through the wall” measurement is intended to demonstrate the versatility of a capacitance measurement.
[0058] FIG. 6 illustrates a chart 600 of oil type sunflower seeds and plastic 6 mm air gun pellets using a measured capacitance example sensor arrangement as taught herein. The plotted data shows the measured capacitance from this apparatus versus the fill level for two different fill materials: oil type sunflower seeds and plastic 6 mm air gun pellets. Also shown in chart 600 are the linear fit equations for the capacitance measurements for both materials. These equations are the calibration expressions that would be used to estimate fill level from capacitance measurement. A well-known weakness of prior art single electrode level measurements is that the calibration curves are dependent on the fill material.
[0059] FIG. 7 illustrates a chart 700 of the sunflower seeds and air gun pellets of FIG. 6 and an estimated fill level versus an actual level when a permittivity independent method is used. In particular, chart 700 shows estimated fill level versus the actual level when a permittivity independent method is used from the ratio of level and reference capacitance measurements. As chart 700 shows, the single permittivity independent method exhibits highly accurate results for both the plastic pellets and the sunflower seeds. Further, with this method no material dependent calibration is required.
[0060] In one example embodiment, a level measurement system as taught herein the electrodes can be mounted either internal to any material container or external to a non-metallic material container with external mounting utilizing an active electrical shield to prevent biasing of the capacitance measurement by external influences such as rain or proximity of other materials.
[0061] In a related embodiment, a level measurement system as taught herein uses the multi-frequency capacitance measurements collected at different fill levels and can be mathematically manipulated so as to estimate the totally empty container capacitance enabling the sensor to be utilized in a single frequency mode for materials with permittivity that is independent of frequency. This single frequency mode taught herein circumvents the need for physical calibration measurements by using the multi-frequency level estimate as the known calibration point for the single frequency measurement.
[0062] The advantages of the various embodiments described herein include but are not limited to providing continuous level information in the form of a frequency output, an analog output, PWM signal, or digital; and providing discrete signals for particular levels (half full, ¾ full, etc.) and the output is linear. Because continuous level sensing is available, the system can also provide flow rate information by differentiating changes in the bin level. In a related embodiment, an active shield is included which removes unwanted external influences from the measurement.
[0063] The following patents that relate to capacitive sensors are herein incorporated by reference in their entirety and constitute part of the disclosure herein: U.S. Pat. No. 6,539,797 and 2006/0236275 to Breed.
[0064] Having thus described several illustrative embodiments, it is to be appreciated that various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements are intended to be part of this disclosure, and are intended to be within the spirit and scope of this disclosure. While some examples presented herein involve specific combinations of functions or structural elements, it should be understood that those functions and elements may be combined in other ways according to the present invention to accomplish the same or different objectives. In particular, acts, elements, and features discussed in connection with one embodiment are not intended to be excluded from similar or other roles in other embodiments. Accordingly, the foregoing description and attached drawings are by way of example only, and are not intended to be limiting.
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A sensor assembly is described herein that can automatically calibrate itself upon installation into an empty bin, eliminating the need to actually fill the bin to calibrate the level reading. The sensor will provide consistent measurement regardless of material properties (permittivity, density, temperature or moisture content). The capacitive nature of the sensor means that in some circumstances, it will sense the material through plastic/glass/fiber glass thereby allowing the sensor assembly to be mountable on the outside of a bin or container. The electrodes of the sensor system are designed to provide a continuous level reading.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a hand lever device for operating a driven member, such as a throttle valve, of an internal combustion engine via a cable. In particular, the hand lever is preferably mounted on a working machine, such as a hedge trimmer or brush cutter, in the vicinity of a hand grip so that it is easy and convenient to operate a throttle valve or the like via a throttle cable or the like.
2. Description of the Prior Art
For example, in a working machine such as a hedge trimmer and brush cutter, an operative portion including a cutting blade or the like is driven by an internal combustion engine. A hand lever device is provided for controlling the degree of opening of a throttle valve of the internal combustion engine. Such a hand lever is mounted in the vicinity of a grip of a U-shaped handle, a bar handle or the like of the working machine so as to provide manual control of the output force of the internal combustion engine.
The hand lever device is generally provided with a throttle trigger (throttle lever) operated by the operator's fingers with the throttle lever being pivotally operated to thereby control the degree of opening of the throttle valve via a throttle cable. In general, the throttle valve is always biased toward the direction of the minimum valve opening that allows the engine to idle. Accordingly, the throttle valve is normally kept at the idle opening position and, when the throttle cable is drawn, it begins to open from the opening position for idling (slow running) of the engine toward an opening position for operation (higher speed running) of the engine.
Such known hand lever devices for controlling throttle valve settings include an automatic return to an idle setting type and an immobilizable type. In the former type, when such a throttle lever is released from a pivotal operation position, the lever is automatically returned to its original idle position setting, thereby moving the throttle valve to its idle setting. In the latter type, when fingers are released from a throttle lever, the throttle lever is immobilized at a desired pivotal operation position (see, for example, Japanese Examined Utility Model Publication No. 19944/1982).
In the auto-return type, when fingers are released from the throttle lever, the engine is automatically returned to idling condition. Consequently, when the auto-return type is used in a working machine, where the output force of the engine is transmitted to an operative portion including a cutting blade via a centrifugal clutch, the centrifugal clutch is disconnected to cut off the transmission of the driving force to the operative portion. Accordingly, the operation of the machinery can immediately be stopped by returning the throttle valve to the opening degree for idle running if an accident occurs, thereby advantageously attaining improved safety. On the other hand, the throttle valve must be held continuously by fingers at a desired pivotal operation position to achieve the desired operation of the machinery. This causes problems in that this type is awkward with respect to intermediate opening degrees, the fingers are susceptible to fatigue, and the speed of the engine is likely to be unstable.
In general, it is desired for operational convenience that a lever which is pivotally operated, for example, a throttle lever be alternatively shifted between two positions, such as a released position and a set position (gripped position) without being suspended at any intermediate position. Accordingly, it is preferred in terms of operability that the lever be set in the same pivotal operation position (set position) regardless of whether an intermediately open condition (partially open condition) or the fully open condition (W.O.T.) of a throttle valve is intended.
On the other hand, the immobilizable type is capable of solving the above problems associated with the auto-return type. The immobilizable type advantageously holds the throttle lever at a desired pivotal operation position without the throttle lever being held by the operator's fingers. This enables an easy cutting operation because fingers are liberated from holding it. However, since additional operation is required to release the throttle lever from the immobilized position, it is impossible to immediately stop the machinery even if an accident occurs. Accordingly, there is a problem that, in terms of safety, the immobilizable type is inferior to the auto-return type.
SUMMARY OF THE INVENTION
The present invention has been made in view of these problems. It is, therefore, an object of the present invention to provide a hand lever device which is free of the above-mentioned drawbacks inherent in the auto-return type and the immobilizable type and which combines the advantages of these types. For example, the hand lever device permits a throttle valve to be appropriately adjusted via a cable to its degree of opening and kept at a desired opening degree, and yet, immediately returned to the opening degree associated with an idle condition. This ensures high safety and diminishes fatigue of fingers and provides preferred operability.
To attain the above-mentioned objective, the hand lever device according to the present invention, as a basic embodiment, comprises:
a housing,
a main lever pivotally attached to the housing,
a spring member fixedly mounted on the main lever, the spring member being bendable in the direction along pivotal movement of the main lever, the spring member having its free end formed into a holder holding a terminal piece of a cable connected to a driven member, and
a stopper for stopping the connection (holder) of the spring member with the cable at a desired drawn position of the cable when the main lever is pivotally operated to draw the cable via the spring member.
The preferred embodiments of the present invention includes one wherein the stopper includes a cam member with an eccentric cam portion, one wherein the spring member is made of a leaf spring, and one wherein the driven member is a throttle valve of an internal combustion engine.
Where the driven member is a throttle valve of an internal combustion engine, a working machine comprises an operative portion including a cutting blade driven by the internal combustion engine whose throttle valve is biased in the direction of a degree of opening that allow the engine to idle. When a throttle cable connected thereto is drawn from a non-operating position, the throttle valve begins to open from the opening position for the idle condition. One form of the hand lever device which is preferably disposed in the vicinity of a hand grip of such a working machine comprises:
a housing,
a main lever pivotally attached to the housing,
a spring member fixedly mounted on the main lever, the spring member being made of a leaf spring bendable in the direction along pivotal movement of the main lever, the spring member having its free end formed into a holder holding a terminal piece of a cable connected to a driven member, and
a stopper for stopping the connection (holder) of the spring member with the cable at a desired drawn position of the cable when the main lever is pivotally operated to draw the cable via the spring member, the stopper including a cam member with an eccentric cam portion.
In the preferred form of the hand lever device according to the present invention, which is constructed as described above, when the main lever is in the released position, the throttle valve is in the minimum opening position that allows the engine to idle. When the main lever is pivotally operated from this position, the throttle cable is drawn via the spring member made of a leaf spring to rotate the throttle valve from the minimum opening position toward an opening position for running of the engine at a higher speed. In the course of the movement of the main lever, the spring member abuts on the stopper. Thus, the connection in the spring member with the throttle cable is consequently interrupted in its movement and kept at a desired drawn position of the throttle cable. On the other hand, the further pivotal movement of the main lever is uninterruptedly continued to the set position, where the outer surface of the main lever is substantially flush with the grip, because of the bending action of the spring member. The bending action of the spring member absorbs the further pivotal movement of the main lever.
Therefore, by preliminarily adjusting the position of the stopper, the drawn position of the throttle cable is determined with respect to the connection in the spring member with the throttle cable. The drawn amount of the throttle cable is thereby controlled. In other words, the degree of opening of the throttle valve is controlled. Further, in the event that it is necessary to immediately lower the speed of the engine due to the occurrence of an accident or the like, the main lever can be completely released. The main lever, spring member, throttle cable and throttle valve are automatically returned to the respective original positions which allow the engine to idle. Consequently, the engine is brought into its idle condition. If the working machine is adapted so that rotational driving force of the engine is transmitted to the operative portion including the cutting blade and the like via a centrifugal clutch, the centrifugal clutch is disconnected to cut off the transmission of the driving force to the operative portion. Thus, the operation of the operative portion including the cutting blade and the like is immediately stopped.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing an example of a brush cutter adopting one embodiment of the hand lever device according to the present invention.
FIG. 2 is a left side view showing the one embodiment of the hand lever device according to the present invention.
FIG. 3 is a sectional left side view of the embodiment shown in FIG. 2 where a throttle valve is in its full open condition.
FIG. 4 is a sectional left side view of the embodiment shown in FIG. 2 where the throttle valve is in its partial open condition.
FIG. 5 is a vertical sectional view of the embodiment in FIG. 2 viewed in the direction of arrow V.
FIG. 6 is a sectional view taken along the line VI--VI and viewed in the direction of the arrows in FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention will be described in more detail with reference to the accompanying drawings.
FIG. 1 shows an example of a brush cutter employing one embodiment of the hand lever device according to the present invention. The illustrated brush cutter 1 comprises a U-shaped handle 7 provided with right and left grips 11, 12 spaced a predetermined distance apart. An operating rod 8 supports the U-shaped handle 7, and an operative portion 3 is provided on the distal end of the operating rod 8. The operative portion 3 includes a cutting blade 13, a safety cover 14 and so forth. The brush cutter 1 further comprises an internal combustion engine 2, for example, a small air-cooled two-cycle gasoline engine, which is disposed on the proximal end of the operating rod 8. The engine 2 provides driving power for driving the cutting blade 13 via a drive shaft 9 extending through and within the operating rod 8. The internal combustion engine 2 is provided with a carburetor (not shown) having a throttle valve CV and a spark plug 5. The combustion engine is also provided with a fuel tank 4 and a recoil starter 6.
In this example, the throttle valve CV is always biased in the direction of a minimum degree of opening (for an idle condition). When a throttle cable 22 connected thereto (as shown in FIG. 2 and described below), is drawn from the non-operating position, the throttle valve CV begins to open from the minimum idle opening position.
One embodiment of the hand lever device 10, according to the present invention, is provided in the vicinity of the grip 11. Grip 11 is the one of the grips 11 and 12 that is gripped generally by an operator's right hand. The hand lever device 10 is used to adjust the degree of opening of the throttle valve CV.
As shown in FIGS. 2 to 4, the hand lever device 10 is located at the head portion of the grip 11 composed of cover members 15A and 15B (hereinafter often referred to simply as cover 15A, 15B). Cover 15A, 15B is clamped together by means of clamping members 26, 27 and 28 such as screws. The hand lever device 10 comprises a substantially fan-shaped main lever 30 pivotally supported at its base end by a pin 31, a spring member 35 made of a leaf spring and having a substantially "dog-legged" shape when viewed sideways, and a stopper 40 in the form of an eccentric cam shaft.
The spring member 35 includes a mounting portion 35a fixedly mounted on the inner side of the main lever 30 by screws 33 and a bendable portion 35b having its free end formed into a tubular holder 34. The holder 34 holds therein a terminal metal piece 24 of a throttle cable (inner cable) 22 extending through and within an outer tube 21 of a Bowden cable 20. The bendable portion 35b has an appropriate spring constant which is selected to overcome the biasing force on the throttle valve CV and to minimize load on the operator's finger while drawing the main lever 30.
As shown in FIG. 5 in addition to FIGS. 2 to 4, the stopper 40 comprises a supporting shaft 42, a cam member 44 with an eccentric circular cam portion 44a, and an adjusting dial 45. The supporting shaft 42 is rotatably supported in the upper end portion of the cover 15A, 15B in parallel with the main lever 30 and has an axis of rotation 0. The cam member 44 with an eccentric circular cam portion 44a is externally fitted on the supporting shaft 42 and fixed thereto by a pin 43. The adjusting dial 45 is fitted on a hexagonal portion 42a provided at one end of the supporting shaft 42 which outwardly protrudes from the cover member 15B and fixed thereto by a screw 46. The adjusting dial 45 has a knurled peripheral surface. The eccentric circular cam portion 44a of the cam member 44 has its center E eccentrically located at a predetermined distance apart from the axis of rotation 0.
Between the adjusting dial 45 and the cover member 15B, a belleville spring 47 is interposed. By adjusting the screw-in amount of the screw 46 under the elastic action of the belleville spring 47, frictional force between the adjusting dial 45 and the cover member 15B is controlled. The adjusting dial 45 is thereby held immobilized at a desired pivotal operation position.
In the hand lever device 10 of this embodiment which is constructed as described above, when the main lever 30 is in the released condition as shown in FIG. 2, the throttle valve CV is in the minimum opening condition that allows the engine to idle. When the main lever 30 is moved from this condition, the main lever 30 is pivotally operated as shown in FIG. 3 or 4. Consequently, the throttle cable 22 is drawn from the outer tube 21 of the Bowden cable 20 via the spring member 35 made of a leaf spring. The throttle valve CV is thereby moved from the opening condition for idling (slow running) of the engine toward an opening condition for operation (higher speed running) of the engine. In the course of the movement of the main lever 30, the spring member 35 abuts on the cam portion 44a of the stopper 40. The tubular holder 34 of the spring member 35, i.e., the connection with the throttle cable 22, is consequently interrupted in its movement and kept at a desired drawn position of the throttle cable. On the other hand, the main lever 30 is further uninterruptedly moved in the pivotal direction to the set position (as shown in FIGS. 3 and 4), where the outer surface of the main lever 30 is substantially flush with the grip 11, because of the bending action of the spring member 35. The bending action of the spring member 35 absorbs the further pivotal movement of the main lever 30 to prevent the throttle cable 22 from being drawn in excess of the desired amount.
Therefore, by preliminarily turning the adjusting dial 45 to adjust the cam portion 44a of the stopper 40 to an appropriate position, the drawn position of the throttle cable 22 is determined with respect to the connection with the throttle cable 22, i.e., the holder 34 of the spring member 35. The drawn amount of the throttle cable 22 is thereby controlled. In other words, the degree of opening of the throttle valve CV is controlled.
For example, in the case where the cam portion 44a of the stopper 40 is set with its eccentric portion positioned up as shown in FIG. 3, when the main lever 30 is fully gripped to move to the set position, the spring member 35 is just brought into contact with the cam portion 44a but not bent. Consequently, as intended, the drawn amount of the throttle cable 22 is maximized and the throttle valve CV is brought into the fully open condition (W.O.T.). On the other hand, in the case where the cam portion 44a of the stopper 40 is set with its eccentric portion positioned down as shown in FIG. 4, when the main lever 30 is fully gripped to the set position, the spring member 35 is pressed against the cam portion 44a and bent downwardly. Consequently, the drawn amount of the throttle cable 22 is smaller than the maximum amount shown in the former case. Thus, the throttle valve CV is brought into an intermediately open condition (partially open condition) of, for example, 50% of the fully open condition. The cam portion 44a may appropriately be modified, for example, in its size or shape, to change the lower limit of the intermediately open condition of the throttle valve CV relative to the fully open condition.
As described above, according to this embodiment, the main lever 30 is alternatively shifted between the two positions, i.e., the released position and the set position (pressed position). Accordingly, the main lever may be set in the same pivotal operation position (set position) regardless of whether an intermediately open condition (partially open condition) or the fully open condition (W.O.T.) of the throttle valve CV is intended. This provides markedly enhanced operability.
Further, in the event that it is necessary to immediately lower the speed of the engine 2 due to the occurrence of an accident or the like, the main lever 30 can be completely released. The main lever 30, the spring member 35, the throttle cable 22 and the throttle valve CV are automatically returned to the respective original positions which allow the engine to idle. In consequence, the engine 2 is brought into its idle condition. If the working machine is adapted so that rotational driving force of the engine is transmitted to the operative portion 3 including the cutting blade 13 and the like via a centrifugal clutch, the centrifugal clutch is disconnected to cut off the transmission of the driving force to the operative portion 3. Thus, the operation of the operative portion 3 including the cutting blade 13 and the like is immediately stopped.
The present invention has been described in detail with reference to the one embodiment. It is, however, to be understood that the present invention is by no means restricted to the illustrated embodiment and that various modifications may be made within the scope which does not depart from the spirit of the present invention as defined in the claims.
For example, in the above example, the hand lever device 10 according to the present invention is used to control the degree of opening of the throttle valve CV of the internal combustion engine 2. The hand lever device of the present invention may, of course, be used in other applications than adjustment of the degree of opening of the throttle valve CV.
Further, the main lever may be a long lever which is held by fingers, instead of the trigger-like lever as illustrated.
Moreover, the hand lever device 10 as such may be used by mounting it on a bar handle and the like beside the U-shaped handle 7.
As understood from the above description, according to the hand lever device of the present invention, the hand lever device permits a throttle valve to be appropriately adjusted via a cable to its degree of opening. The throttle valve can be kept at a desired opening degree, and yet, immediately returned to the opening degree associated with an idle condition. This ensures high safety and diminishes fatigue of fingers and provides preferred operability.
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A hand lever device which is capable of combining high safety with excellent operability. The hand lever device includes a housing and a main lever pivotally attached to the housing. A spring member is fixedly mounted on the main lever, and is bendable in the direction along pivotal movement of the main lever. The spring member has a free end formed into a holder holding a terminal piece of a cable connected to a driven member. A stopper stops the holder of the spring member with cable at a desired drawn position of cable when main lever is pivotally operated to draw cable via spring member.
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CROSS-REFERENCES TO RELATED APPLICATIONS
This application is a non-provisional of, claims priority to, and incorporates in its entirety previously-filed U.S. Provisional Application No. 61/782,599, filed on Mar. 14, 2013. This application is related to PCT/US14/27306, Positive Penetration Wood Handling Apparatus, filed on Mar. 14, 2014.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable
BACKGROUND
The related art of interest describes various wood and log handling apparatus used for dragging and lifting wood. Existing apparatuses, including but not limited to chains, tongs, hooks, clamps, vice, log claw and timber carriers, suffer notable deficiencies. For example, wood handling apparatuses known to the art often fail to achieve positive penetration into wood. Such apparatuses are also frequently unable to maintain a secure hold when the angle of force between the handling apparatus and the item being handled changes, such as when a handling apparatus is used to assist dragging a log across the ground or positioning it for splitting in a log splitter. Known apparatuses are required to be repositioned virtually every time the angle or orientation of the item to be handled is changed. Many handling apparatuses known to the art rely on resistant force to connect to the item being handled, such as tongs and clamps. Such apparatuses often are or become insecure during the handling procedure, and the connection based entirely on resistant contact is prone to slippage or failure.
There is a need in the art for a wood handling apparatus that anchors securely to wood, is easy to attach, and maintains a secure connection without needing to be repositioned or reattached when the angle of force between the apparatus and wood being handled changes, such as during dragging, lifting, and positioning.
SUMMARY
The present invention addresses this need by providing an ergonomic, quickly attachable wood handling apparatus that provides a secure connection through positive penetration for lifting, dragging, shifting, twisting, rotating, or otherwise moving wood to be handled without needing to readjust or reposition the apparatus when the wood changes angle or orientation. In some embodiments, the present invention comprises a main shank connected to a support member, with the support member connected to a drive handle. Optionally, a connection member may also be connected at one end to the support member and at the other end to one or more of the drive handle and the main shank.
In a preferred embodiment, the main shank is threaded and pointed to facilitate penetration into wood. The main shank is connected to a support member, which support member comprises a member bisecting the drive handle. In a preferred embodiment, the support member is a bar that is, when viewed from an edge-on perspective, U shaped. The support member is connected to a drive handle, which comprises a handle adapted to facilitate grasping and the exertion of rotational force on the apparatus by a user. In a preferred embodiment, the drive handle comprises a wheel. Said support member further optionally connects to a connection member, which comprises a rod, strut, or other connection point adapted to facilitate connection of the apparatus to a cable, hoist, lift, rope, or other transportation means. In a preferred embodiment, the connection member is a bent strut attached at one end to the lowermost portion of the support member and at the other end to the drive handle. Optionally, the drive handle can comprise the connection member. The connection member can optionally be used as a handle for handling of the wood to which the apparatus is connected, or can be interfaced with a hook, chain, cleavice, swivel, cable, sling or rope for further handling.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features, aspects and advantages of the present invention will become better understood with regard to the following description and accompanying drawings, where:
FIG. 1 is a top-down view of a preferred embodiment of the present invention;
FIG. 2 is a side view of a preferred embodiment of the present invention;
FIG. 3 is a top-down view of one alternative embodiment of the present invention, in which the drive handle comprises a bar;
FIG. 4 is a side view of one alternative embodiment of the present invention, in which the drive handle comprises a bar;
FIG. 5 is a side view of one alternative embodiment of the present invention, in which the drive handle also comprises the connection member;
FIG. 6 is a side view of one alternative embodiment of the present invention, in which the drive handle also comprises the support member.
DESCRIPTION
The present invention relates to embodiments of a wood handling apparatus that provides a secure connection for lifting, dragging, shifting, twisting, rotating, or otherwise moving wood to be handled without needing to readjust or reposition the apparatus when the wood changes angle or orientation. The apparatus taught herein comprises a main shank connected to a support member, a support member connected to a drive handle, said support member also optionally connected to a connection member to facilitate handling or lifting of the apparatus by hand, or by cable, hook, cleavice, or other similar device.
“Wood” as used herein includes all wood and wood-like materials, regardless of shape, size, purpose, or general composition, desired to be handled and known to those skilled in the art to be capable of retaining a screw or lag screw. “Wood” includes but is not limited to stumps, logs, branches, limbs, posts, joists, rafters, runners, boards, trim, dimensional lumber, rough-cut lumber, and wood-like composites.
As shown in FIGS. 1 and 2 , in a preferred embodiment the invention is a wood handling apparatus comprising a drive handle [ 1 ] connected to a support member [ 3 ]. The support member [ 3 ] is connected to a main shank [ 5 ]. The support member is in this embodiment further connected to a connection member [ 7 ]. The connection member [ 7 ] is in this embodiment a bent strut, connected at one end to the support member [ 3 ] and at the other end to the drive handle [ 1 ], thereby forming a secondary handle or an attachment point for a cable, hook, rope, sling, swivel, carabineer, cleavice, or other similar device. In this preferred embodiment the drive handle [ 1 ] is a wheel, although it will be appreciated that other shapes and geometries of drive handle may be used within the scope of the present invention. In this embodiment, the support member [ 3 ] is a bar bisecting the drive handle that is “U-shaped” when viewed from an edge-on perspective with reference to the apparatus, although it will be appreciated that other structures may be used within the scope of the invention, so long as they are adapted to permit the exertion of rotational force on the shank [ 5 ] by exerting force against the drive handle [ 1 ]. For example, the support member [ 3 ] could optionally comprise a straight bar bisecting the diameter of the drive handle [ 1 ], or a bent or straight bar extending only the length of the radius of the circle described by a circular drive handle [ 1 ] to connect the drive handle [ 1 ] to a shank located at the center of the circle described by a circular drive handle [ 1 ]. The main shank [ 5 ] is preferably a conical, pointed, threaded shank, of sufficient thickness and with sufficiently coarse threads to facilitate the lifting of heavy wood. It will be appreciated that unthreaded shanks, shanks of other shapes, and shanks with varying thread coarseness are within the scope of the invention, provided that the shanks is adapted to achieve positive penetration into wood to form a connection to wood through impact, rotation, or a combination of impact and rotation.
Optionally, embodiments herein may comprise a connection member [ 7 ]. In such embodiments, the connection member [ 7 ] comprises generally a strut or bar, preferably bent, connected at one end to the support member [ 3 ] and at the other end to one or more of the main shank [ 5 ] or drive handle [ 1 ] such that the connection member serves as a secondary handle or a connection point for a hook, chain, swivel, rope, sling, cable, hook, carabineer, cleavice, or other similar device. It will be recognized by one skilled in the art that the drive handle [ 1 ] itself, the support member [ 3 ] itself, or any aperture or protrusion on the support member [ 3 ] or drive handle [ 1 ] capable of facilitating connection of the apparatus with a hook, chain, cleavice, swivel, cable, sling or rope for further handling can comprise the optional connection member [ 7 ].
In use, the embodiment of the present invention shown in FIGS. 1 and 2 would operate as follows: a fireplace log is lying on the ground in the horizontal position. The apparatus is grasped using both hands on the drive handle [ 1 ]. The main shank [ 5 ] of the apparatus is pushed against the side of the log. The drive handle [ 1 ] rotated to achieve positive penetration of the main shank [ 5 ] into the wood. Rotation is continued until the support member [ 3 ] contacts the wood. The apparatus can then be used to lift, drag, or otherwise manipulate the log, including by attaching cables or hoists to the connection member [ 7 ] or drive handle [ ] for the purpose of moving the log through mechanical force.
Although the present invention is described with reference to specific embodiments herein, it will be appreciated by one skilled in the art that other sizes, shapes, configurations, and methods may be used within the scope and spirit of the claims herein.
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An apparatus for positive retention of wood connects to and retains wood for transport and handling, the apparatus comprising a drive handle connected to a support member, the support member connected a main shank, and the main shank adapted to positively penetrate wood through one or more of impact and rotation, wherein the main shank forms a connection to the wood after such positive penetration is achieved.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable
BACKGROUND OF THE INVENTION
[0002] This invention relates to the luring of waterfowl to any general area during any season. Traditionally, waterfowl lures were in the form of waterfowl decoys. These decoys were commonly three-dimensional life-like models of a particular species of waterfowl, which were placed in water or in a food plot to mimic living waterfowl. Living waterfowl were then attracted to the general area of the decoys. The general problem with traditional waterfowl lures is that the decoys had to be placed in non-frozen water or in a food plot. Further, traditional geese decoys were expensive, large and difficult to deploy effectively. Therefore, traditional waterfowl lures were minimally effective during a freezing winter, an area that lacked water, or an area not a food plot.
[0003] When seasons and topography allowed the use of traditional waterfowl decoys, it was common practice to arrange several dozen decoys in an area of a natural waterfowl habitat. A significant problem with using this many decoys was the weight and bulk involved in transporting and deploying the decoys to and from the site. It was quite time consuming to deploy several dozen decoys in an appropriate display that would attract living waterfowl. Further, the area of deployment had to contain non-frozen water or the food or nourishment sought by waterfowl.
SUMMARY OF THE INVENTION
[0004] This invention utilizes a large ground covering that is attached over land or frozen water. On the top-side of the ground covering is an artistic print that resembles unfrozen water, with some prints having waterfowl swimming or landing thereon. The artistic print of unfrozen water may be that of a river, channel, pond, or lake, complete with a vegetated or snowy bank. Other prints will mimic an unfrozen hole in the ice of an otherwise frozen pond or lake. Additional prints will mimic waterfowl food plots, such as a harvested cornfield. The invention can vary depending upon the user's need. The object of this invention is to simulate an unfrozen waterfowl habitat or a typical food plot that will lure living waterfowl to the general vicinity of the ground covering. Waterfowl hunters and waterfowl photographers will benefit from this invention.
[0005] This invention solves the previous problems of luring waterfowl, using traditional waterfowl decoys, during a freezing winter, an area lacking water, or an area not a food plot. This invention can be deployed in any season and over land, snow or frozen water. Further, by virtue of mimicking food plots or non-frozen water, this invention will make barren areas, or areas not otherwise attractive to waterfowl, capable of luring waterfowl.
[0006] This invention also alleviates the bulk and burden commonly associated with transporting and deploying several dozen traditional decoys. This invention can be folded up to a compact size, which is easier to transport. This invention can also be made using lightweight synthetic cloth.
[0007] Finally, this invention is quicker and easier to deploy than traditional decoys because deployment of this invention simply involves attaching the ground covering to the underlying surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Not applicable
DETAILED DESCRIPTION OF THE INVENTION
[0009] The preferred embodiment of this invention utilizes a 12-ounce, stretchable, reinforced outdoor vinyl mesh, which is to become the ground covering. This vinyl mesh is commonly used for outdoor billboards and large advertisements placed on the exterior of buildings. Benefits of this material include it being readily obtainable, non-reflective, waterproof, resistant to ultraviolet radiation, and that an artistic computer-generated print can be readily applied. This material can also be folded for compact storage and transportation. Further, because the vinyl mesh consists of small interwoven vinyl strips, this material can withstand wind. Canvas would also suffice as an alternative to the vinyl mesh, with some of the same benefits as the vinyl mesh. Other materials, from natural fabrics like cotton, to synthetic polymers like nylon, will also suffice.
[0010] The ground covering should contain a means to attach it to the underlying surface, whether the underlying surface be land, snow or frozen water. The preferred means of attaching the ground covering utilizes eyelets placed along the outside edge of the ground covering at regularly spaced intervals. The eyelets should be made of non-reflective material, or painted with non-reflective paint, so waterfowl will not be distracted. These eyelets allow the user to stake or tie the ground covering to any type of underlying surface. These eyelets also allow the user to adjacently join two or more ground coverings to create a single, larger ground covering. Velcro and/or buttons may also be sewn into the outside edges of a ground covering to assist in adjacently joining two or more ground coverings. Besides eyelets, a user may sew sleeves into the outside edge of the ground covering. The user could then thread rope or poles through the inside of the sleeve, and then use to the rope or poles to attach the ground covering to the underlying surface.
[0011] The size and shape of this ground covering will vary depending upon the user's needs. The shape need not be square or rectangular. The five most common uses of this ground covering will be to simulate an unfrozen river, an unfrozen pond or lake, an unfrozen channel, an unfrozen hole in an otherwise frozen pond or lake, or a food plot. The user will select the particular simulation depending upon the natural environment in which the user desires to place the ground covering. For a ground covering mimicking an unfrozen river, the preferred size is a rectangular 14 feet by 48 feet because this is a common size for outdoor billboards, which makes this shape readily obtainable. A shape larger and less narrow, such as 30 feet by 60 feet, work well for ground coverings mimicking an unfrozen pond, lake, channel or an unfrozen hole in an otherwise frozen pond or lake. These and larger sizes, dependent upon the user's needs, suffice for mimicking a food plot.
[0012] The top face of the invention will have the artistic print that attracts waterfowl. The preferred method of generating this print utilizes a color, computer generated, digital graphic at a resolution between 70 to 600 dots per inch. An effective alternative is to use a four-color screen-printing process. Alternatively, the invention can be manufactured by dying the ground covering a particular color to simulate water, then enhancing the edges of the ground covering with a pattern mimicking vegetated ground, frozen water, a food plot, or the surrounding environment. A print may also be applied using a more traditional paint and brush method. The print, when applied to the ground covering, should be opaque when viewed from a distance, but may be transparent when viewed up close (as will be the case if a vinyl mesh is used as the medium). The print may contain waterfowl of one or some particular species (depending upon the type of waterfowl the user wishes to lure), portrayed as swimming, landing, or flying. The purpose of adding waterfowl to the print is to increase the realism of the print and to attract waterfowl that tend to flock. A user could also place traditional three dimensional waterfowl decoys on the print. For prints mimicking a river, channel, pond or lake, the preferred print will contain a vegetated shoreline that resembles the natural vegetation where the ground covering is to be used. For prints mimicking an unfrozen hole in an otherwise frozen pond or lake, the edges of the print should resemble the natural frozen water where the ground covering is to be placed. The interior of this type of print will resemble unfrozen water. For prints mimicking a food plot, the print should resemble the particular waterfowl's food source, which is commonly a field of alfalfa, winter wheat, or harvested corn. For any print, it is important that the overall effect of the print resemble the particular season and environment in which it is to be used.
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A waterfowl lure used to attract waterfowl to a general area, comprising of a ground covering with an artistic print on its top face that mimics unfrozen water or a food plot, the purpose of which is to simulate a natural waterfowl habitat. The print may also contain portrayals of living waterfowl. The ground covering can be attached to any type of underlying surface, whether land, snow or frozen water.
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BACKGROUND OF THE INVENTION
[0001] The invention relates to a flap system for an aircraft high lift system or an engine actuation with a rotary shaft system, one or more drive stations as well as elements for transmitting the drive energy from the rotary shaft system to the one or more drive stations. Furthermore, the invention relates to a method for monitoring such flap system.
[0002] Aircraft high lift systems adapt the wing profile to the respective flight situation by means of a suitable flap mechanism. What is known are aircraft high lift systems with a central drive unit in the form of a rotary shaft system which is connected with one or more drive stations via branch transmissions. These drive stations each comprise an appropriate drive which converts the rotational energy provided by the rotary shaft system into the appropriate flap kinematics.
[0003] Up to now, two individual drives are used per flap. Flaps arranged one beside the other are connected with each other via mechanical coupling points, so-called interconnection struts, in order to prevent skewing of the flap during extension and retraction in the case of the failure of a drive. In the case of the failure of a drive station, the load path extends to the adjacent flap via the interconnection strut.
[0004] This mechanical connection between the flaps, however, prevents the implementation of an extended flap functionality, in particular the possibility of an adaptive camber of the wing profile by means of differential flap positioning over the wingspan. For realizing such extension function, the previously provided mechanical coupling path between the flaps must be omitted. By omitting the coupling, however, the redundancy is lost and a novel safety concept is required for protection against structural faults.
[0005] An identical or similar flap system is used in the engine actuation of an aircraft engine. By means of the flap kinematics the function of a thrust reversal can be realized.
SUMMARY OF THE INVENTION
[0006] The object therefore consists in finding a novel technical solution for the mechanical arrangement of the elements of a flap system for an aircraft high lift system or an engine actuation, which provides for the realization of the described extended functional requirements and nevertheless ensures a sufficient safety-related protection of the construction.
[0007] This object is solved by a flap system according to the features herein. This system comprises a rotary shaft system, one or more drive stations as well as elements for transmitting the drive energy from the rotary shaft system to the one or more drive stations. According to the invention, at least one drive station includes at least two independent load paths with at least one rotational transmission each for actuating the flap kinematics. By means of the rotational transmission, the drive-side torque of the rotary shaft system or its rotational speed is converted into the desired setpoint speed or setpoint torque, in order to produce the desired flap movement by means of a suitable flap mechanism.
[0008] In the arrangement according to the invention it is decisive that between the redundant load paths of the drive station no mechanical coupling exists, i.e. the two load paths operate in parallel completely independent of each other. Both load paths are active during the regular operation, i.e. the desired flap movement is effected by both load paths. Particularly advantageously, the necessary load moment for the flap actuation is distributed on both load paths in equal or almost equal proportions. As compared to known linear drives, rotational drives require distinctly less maintenance, which is why the incurred operating costs of the aircraft systems can be minimized by the use of rotational drives according to the invention.
[0009] In previous systems with interconnection struts high fault loads are obtained in the case of an interruption of a simple load path, which due to the mechanical coupling proportionately have an effect on the intact station. These fault loads must be taken into account in the design of the flap bodies, the flap guiding mechanisms and the actuators. Since the load distribution at the drive stations of a landing flap can be distinctly unsymmetrical, e.g. in a ratio of 1:3, in particular the elements of the stations loaded less in normal operation must be oversized by a multiple. These problems can be avoided completely by the mechanical decoupling between the flaps according to the invention, because the fault “disconnect of a drive station” is excluded by the redundancy in the drive station.
[0010] According to the invention, at least one mechanically coupling-free synchronization unit furthermore is provided per load path for compensating regular load fluctuations between the load paths. In fault-free operation, the station load automatically is distributed on the provided load paths in equal proportions. The prevailing load equilibrium can be impaired, however, due to different drag torques, clearances, efficiencies and adjustment errors (rigging) of the load paths. In the extreme case, the imbalance resulting therefrom can be more the +1-25% of the maximum value of the station load. In particular for monitoring purposes of the flap system according to the invention it is necessary to achieve a compensation of these load fluctuations between the load paths. In concrete terms, an independent synchronization of the transmitted load components of the individual load paths can be effected, wherein this synchronization remains largely free of repercussions within the respective load path. No power transfer occurs between the two load paths. Upon occurrence of an interruption of one of the load paths, the remaining load path can take over the entire load of the drive.
[0011] The flap system according to the invention is suitable for use in an aircraft high lift system for actuating the flaps arranged at the wings. The system however also is usable without limitation in certain systems for engine actuation of an aircraft by means of flaps. In particular, this includes the actuation of the thrust reversal by means of a flap arrangement. For the sake of simplicity, advantageous aspects will be described below with respect to an aircraft high lift system. However, the aspects equally apply for use in the engine actuation and in particular do not limit the subject-matter to the use in aircraft high lift systems.
[0012] In a preferred aspect of the invention, at least one synchronization unit substantially consists of a torsion spring whose spring rate is designed such that in fault-free operation the asymmetry of the load distribution does not exceed a range of +1-25% of the maximum value of the operating load. The construction preferably can be a torsion bar or a ball ramp mechanism biased with springs.
[0013] In a preferred conceptional design of the invention, the aircraft high lift system comprises a flap mechanism with lever and push rod.
[0014] The lever mechanism transforms the rotational movement of the driven shaft of the rotational transmission into a translational movement for the actuating movement of the landing flap. The push rod transmits the actuating energy to the landing flap or its guide mechanism. The concept according to the invention can, however, also be employed for other comparable guide mechanisms, including for example rack & pinion, track & rear link, curved track, 4-bar linkage, 6-bar linkage, etc.
[0015] Monitoring the proper function of the aircraft high lift system according to the invention will be effected in a sensor-based manner. For this purpose, at least one load sensor expediently is arranged on the output side of each rotational transmission. The output-side torque of the individual load paths thereby can be monitored and be compared with each other.
[0016] Furthermore, it is expedient to provide at least one overload fuse per rotational transmission on the drive side. In the fault case of jamming in one of the load paths, the same is protected against overload by a mechanical overload fuse present at the input of the station. The jammed load path possibly is interrupted by the overload fuse. In this case, the remaining intact path takes over the total load.
[0017] Expediently, the state of the mechanical overload fuse is monitored and detected by one or more state sensors. At least one state sensor can be designed in the form of a proximity switch. Instead of the mechanical overload fuse appropriate load sensors also can be employed, which are arranged on the drive side of the rotational transmissions and by means of an electronic evaluation unit detect the state of the drive train with regard to an overload due to jamming.
[0018] Ideally, there is provided an electronic control unit which in dependence on the sensor values monitors the proper function of the aircraft high lift system and in a case of fault generates a corresponding fault message. This fault message not only can indicate the case of fault, but at the same time can identify and/or localize the existing case of fault to a certain extent.
[0019] It is conceivable that the control unit includes means for calculating a difference value between the load moments measured on the output side of the respective rotational transmissions.
[0020] The construction of the aircraft high lift system according to the invention is usable for a large part of known flap guiding mechanisms. For example, the aircraft high lift system can be constructed according to the model of a Fowler flap system, which preferably allows a differential flap positioning in terms of wingspan.
[0021] In principle, the idea of the invention also can be applied to other aircraft high lift systems, for example to a simple hinge or dropped hinge system.
[0022] Beside the flap system according to the invention, the invention relates to a method for monitoring a flap system for an aircraft high lift system or an engine actuation, in particular a thrust reversal. It is essential for the method that the flap system includes at least two redundant load paths per flap, which each comprise at least one rotational transmission. Ideally, the method serves for monitoring a flap system according to the present invention or an advantageous configuration of the flap system according to the invention.
[0023] The monitoring method according to the invention is suitable for monitoring an aircraft high lift system for actuating the flaps arranged at the wings. The system however also is usable without limitation for monitoring an engine actuation of an aircraft by means of flaps, in particular the thrust reversal. For the sake of simplicity, advantageous aspects of the method will be described below with respect to an aircraft high lift system. However, the aspects equally apply for use in the engine actuation and in particular should not limit the subject-matter to the use in aircraft high lift systems.
[0024] In the monitoring method it now is cyclically checked whether the difference of the output-side torques of the at least two load paths, i.e. of the torques at the output shaft of the used rotational transmissions, exceeds a defined threshold value and/or lies within a defined limit range.
[0025] Since in the ideal case the total load for flap actuation in proportion is equally distributed on both load paths, an existing fault case can be inferred with a certain deviation of the individual load moments.
[0026] Ideally, regular load fluctuations in the individual load paths are compensated by integrated synchronization units per load path, such as for example one or more torsion springs or spring-loaded ball ramp mechanisms, so that a regular load fluctuation does not directly lead to the detection of a case of fault. Thus, different clearances, frictions, efficiencies and adjustment errors within the separate load paths can cause these regular deviations of the measured load values from the actual air loads. This kind of deviation however should not influence the correct evaluation of the signals and the correct fault indication. Therefore, it is particularly advantageous when the defined threshold values or tolerance ranges consider the influence of this effect, in order to ensure a robust fault monitoring. For example, it is recommendable to introduce and consider an offset value when calculating the difference of the load moments.
[0027] It is conceivable that the flap system includes at least one overload fuse per load path, which in a case of fault interrupts the respective load path as soon as the existing torque exceeds a certain limit value. In a particularly preferred aspect of the method the drive-side state of the load path, i.e. in particular the state of the overload fuse, now is queried continuously. On the basis of the drive-side and output-side check of the load paths, the method creates a fault image, which not only provides for the easy detection of a fault, but at the same time provides for a first identification and/or localization of the fault that has occurred. Preferably, the fault identified is represented by a binary fault code. The fault image or the binary fault code then can be forwarded to a next higher control hierarchy for the further control logic.
[0028] By means of the monitoring system according to the invention an interruption within one of the load paths thus can be detected, i.e. a jamming in one of the load paths or a jamming in the flap mechanism can reliably be detected and diagnosed. The sensor-based monitor concept thus fulfills the demand for a detection and display system for all conceivable cases of fault. It hence is ensured that upon occurrence of a fault the same is detected within a flight cycle. The probability for the occurrence of a dormant fault largely is reduced. The flight cycle defines the time from an event of the present flight up to the repeated same event during the next flight. From the combination of the available sensor signals the kind of fault and the fault location can be determined unambiguously.
[0029] This now leads to the fact that during the lifetime of an aircraft no special maintenance measures are required at the system, since both the fault detection and the fault identification are effected automatically by the method according to the invention and no manual diagnosis is required. Merely a manual repair becomes necessary.
[0030] The presented monitoring method according to the invention preferably is carried out cyclically during the flight operation. After the first activation, i.e. yet before starting the flight operation, the monitoring method can carry out a one-time system check. It is expedient when the instantaneous values of the respective load sensors are checked against a corresponding threshold value. Checking of the state sensors of the overload fuses likewise can be effected. When all initial checking steps are free from faults, the flight operation is cleared and the corresponding status message is generated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] Further advantages and properties of the invention will be explained below with reference to an exemplary embodiment illustrated in the Figures, in which:
[0032] FIG. 1 shows a schematic representation of the aircraft high lift system according to the invention,
[0033] FIGS. 2A and 2B show a representation of the load sensor signals in the fault-free case, and
[0034] FIGS. 3A and 3B show a representation of the load sensor signals in the case of fault.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] FIG. 1 outlines the structure of the aircraft high lift system according to the invention. The Figure shows the rotary shaft 1 of the landing flap drive system, which transports the necessary actuating energy from a central drive unit to the respective drive stations. The Figure shows exactly one drive station with two redundant load paths with one actuator each, which both operate independent of each other and are operated in parallel in the active mode.
[0036] Each load path comprises a branch transmission 2 a , 2 b by means of which the energy of the rotary shaft system 1 is withdrawn and supplied to a separate mechanical overload fuse 3 a , 3 b . The mechanical overload fuses 3 a , 3 b are designed in the form of a known torque limiter (or torque brake), which in normal operation forward the supplied actuating energy to the succeeding synchronization units 4 a , 4 b . When the applied torque in the respective load path exceeds a certain limit value, the respective overload fuse 3 a , 3 b interrupts its load path. Then, no more load component can be transmitted via the separate load path. The remaining intact load path completely takes over the total load for the flap actuating movement. Responding of the overload fuse 3 a , 3 b is detected by the respective state sensors 10 a , 10 b and communicated to a central control unit. The state sensors 10 a , 10 b are designed in the form of simple switches or proximity switches.
[0037] Alternatively, instead of the mechanical overload fuses 3 a , 3 b with the state sensors 10 a , 10 b , there might also be used load sensors in conjunction with an electronic evaluation unit which in a case of overload detects a fault with reference to the measured torque and takes corresponding countermeasures.
[0038] The setting of the response values of the overload fuses for example is 65% of the maximum total operating load. When the load imbalance becomes too large due to a fault, the load component of the load path subjected to a higher load will increase and the fuse will pop out. Depending on the instantaneous value of the operating load upon occurrence of the fault, one or also both overload fuses can respond.
[0039] In fault-free operation, the station load automatically is distributed on the two load paths at 50% each. The load equilibrium, however, is impaired differently by different drag torques, clearances, efficiencies and adjustment errors (“rigging”) within the two load paths. The resulting imbalance between the load paths can be more than +1-25% of the maximum value of the station load. For this reason, the synchronization units 4 a , 4 b succeeding in the drive train are used, which contribute to the compensation of the different clearances, drag torques, efficiencies or adjustment errors in the respective load paths. The synchronization units 4 a , 4 b consist of a torsion spring whose spring rate is designed such that in fault-free operation the asymmetry of the load distribution does not exceed a range of +1-25% of the maximum value of the operating load. The concrete construction of the units 4 a , 4 b for example can comprise a torsion bar or a ball ramp mechanism biased with springs.
[0040] The torque is passed on from the synchronization units 4 a , 4 b to the succeeding transmission units 5 a , 5 b , which are necessary for compensating directional and positional differences of the connection between branch transmission 2 a , 2 b and rotational transmission 6 a , 6 b.
[0041] The rotational transmissions 6 a , 6 b transform the input shaft power of the rotary shaft system 1 from low torque and high speed into the required output shaft power from high torque at low speed. The transmission 6 a , 6 b is attached to the structure 11 of the aircraft. The output shaft of the rotational transmission 6 a , 6 b is connected with the lever mechanism 8 a , 8 b . The torque sensors 7 a , 7 b continuously measure the shaft torque of the output shaft of the rotational transmission 6 a , 6 b and forward the detected measurement values to the central control unit.
[0042] The lever mechanism 8 a , 8 b transforms the rotational movement of the drive shaft of the rotational transmission 6 a , 6 b into a translational movement for the actuating movement of the landing flap. The actuating movement is transmitted to the landing flap or its guide mechanism by means of the push rods 9 a , 9 b.
[0043] The state sensors 10 a , 10 b of the overload means generate a discrete signal which in normal operation of the system corresponds to an “On” or “High”. An activation, i.e. responding of the overload fuse 3 a , 3 b , changes the signal into “Off” or “Low”. With this signal logic it is achieved that a sensor error does not remain undiscovered, i.e. remains undetected in the form of a dormant fault and will only be noticed in the case of certain actions.
[0044] The non-illustrated electronic evaluation unit serves for monitoring the drive station, the detection of mechanical faults and their indication. It processes the signals of the load sensors 7 a , 7 b and of the state sensors 10 a , 10 b by the following method according to the invention.
[0045] The monitor system consists of three sequentially proceeding monitor cycles. Each monitor run results in a fault status signal of the form 0 (no fault) or 1 (fault). The individual fault status signals then can be combined to a common binary code and be issued. Each binary codes symbolizes an individual fault image.
[0046] During the initialization phase, i.e. after switching on the system, a so-called “pre-flight check” is carried out once. It thereby is ensured that the individual sensor signals themselves are not faulty and the sensors 7 a , 7 b , 10 a , 10 b operate properly. After initially switching on the monitoring system, the control unit therefore reads in the instantaneous values of the load sensors 7 a , 7 b . When the instantaneous values lie within defined limit values, a fault-free sensor operation is assumed. When the instantaneous values exceed defined limit values, the presence of a sensor fault is inferred and a fault message is generated and displayed. Subsequently, the control unit reads in the signals of the state sensors 10 a , 10 b of the overload fuses 3 a , 3 b and evaluates their discrete signal values. In a case of fault, the state sensors issue a signal value of “Zero” or “Low” and the control unit detects and generates an appropriate fault message. In fault-free operation, i.e. both sensors 10 a , 10 b generate output values with the value “Unity” or “High”, a fault-free operation of the monitoring system is assumed and the first monitoring algorithm for the regular flight operation is started.
[0047] This first monitor serves for detecting the load distribution and is repeated continuously during the entire flight. The result of the monitor run is documented correspondingly in the control unit and stored temporarily for future retrieval.
[0048] The control unit continuously reads in the instantaneous values of the load sensors and based thereon calculates the differential amount from the signal values or load values. As long as the differential amount is smaller than a predefined threshold value which defines the limits of the so-called “blind zone” (the value lies within the blind zone), a fault-free operation is assumed and documented correspondingly. In this case, the succeeding monitor is started for detecting jammings, which will yet be explained at a later stage of this description.
[0049] “Blind zone” is understood to be the load range below the guaranteed minimum load (“minimum daily load”). In this zone, no robust monitoring is possible, the results of the individual monitors are not exploited. The limits of the “blind zone” are calculated by the control unit from the instantaneous values of the torque sensors 7 a , 7 b.
[0050] When the calculated differential amount of the sensor values, however, is greater than the predefined threshold value, the air load is greater than the guaranteed minimum load. The control unit then calculates the sum of the instantaneous values of the torque sensors 7 a , 7 b and therefrom deducts the double voltage value of the sensor output at the load 0. When this value lies within the threshold values which define the limits between fault-free operation and faulty operation, a fault-free operation is assumed and correspondingly stored temporarily. Here as well, the execution of the succeeding monitor follows for detecting flap jamming.
[0051] When the value lies outside these threshold values, a fault of the system is detected. The control unit then generates an appropriate fault message and stores the same for the subsequent retrieval. The succeeding monitor for detecting flap jammings will be started.
[0052] This monitor for detecting the flap mechanism or a state of jamming is repeated continuously during the flight operation. The monitor result is documented and stored temporarily in the control unit.
[0053] During the monitor cycle, the control unit reads out the instantaneous values of the state sensors 10 a of the overload fuse 3 a and evaluates the discrete signals obtained. When the signal of the sensors 10 a is an “On” or “High”, a fault-free signal is generated and stored temporarily. When the signal of the sensors 10 a provides a “Zero” or “Low”, a fault signal is generated and stored temporarily.
[0054] The same procedure is carried out for the second sensor 10 b . After the complete query cycle of the above-described monitors, the evaluation cycle or evaluation monitor finally is started.
[0055] During the evaluation cycle, the control unit generates a corresponding fault code from the temporarily stored fault status signal of the first and second monitor for the future representation and evaluation. With reference to the generated fault code the determined type of fault can be inferred exactly. The type of fault is forwarded to a next higher system hierarchy.
[0056] When a fault-free state exists, the next monitor run is started, starting with the first monitor.
[0057] With reference to the measurement values of the load sensors 7 a , 7 b , the monitor system thus can detect an asymmetric distribution of the load on the individual load paths and generate a corresponding fault message. In the fault case of jamming in one of the load paths the corresponding mechanical overload fuse 3 a , 3 b is tripped, which is detected by the associated state sensor 10 a , 10 b and communicated to the controller. The fault message generated thereupon thus identifies jamming within one of the load paths.
[0058] In the fault case of jamming of the flap body, the load symmetry is maintained. In this case, both overload fuses 3 a , 3 b would respond and generate a corresponding fault image. However, when a fault image is generated which on the one hand describes an asymmetric distribution of the load on the load paths and at the same time issues fault cases for both overload fuses, an invalid state is detected and an unknown malfunction of the monitoring system is assumed. The monitoring system then is switched off with a corresponding fault message.
[0059] FIGS. 2 a , 2 b show the signal course of the torque sensors 7 a , 7 b in the fault-free state. Due to different clearances, frictions, efficiencies and adjustment errors a certain torque deviation between the load paths can occur in the individual load paths, i.e. the measured load values differ from the actual air loads. For the correct evaluation of the signals of the load sensors 7 a , 7 b this torque offset value should, however, not influence the correct fault detection. The used threshold values 15 , 16 therefore must consider the influence of these effects, in order to ensure a robust fault monitoring. The hatched area designates the “blind zone” explained above.
[0060] FIG. 2 a shows an operation without influencing signal values, while in FIG. 2 b a unilateral maximum influencing of signal values is present in the range of 700 Nm. This leads to a deviation of the calculated value
[0000] A+B−n,
[0000] wherein A represents the load value of the sensor 7 a and B represents the load value of the sensor 7 b , and n corresponds to twice the voltage value of the sensor output at the load 0.
[0061] The two FIGS. 3 a , 3 b show the signal course of the sensor values of the load sensors 7 a , 7 b after an interruption of the load path a. The measured load moment of the sensor 7 a hence is 0. Analogous to FIG. 2 b , FIG. 3 b shows a unilateral maximum influencing of signal values in the range of 700 Nm.
[0062] On the actuator level it should be stated as an advantage that the method according to the invention provides for reduced maintenance costs by using rotational drives. In addition a passive, automatic load synchronization is effected, which due to the largest possible mechanical decoupling between both load paths also is free of repercussions. There is no power transfer between the two load paths.
[0063] Using a differential transmission instead of the two synchronization units 4 a , 4 b would have the disadvantage that this would produce an inadmissible coupling point between the two load paths, which in the case of a breakage would lead to the complete failure of the system. The same also applies for the use of a beam balance, which likewise would produce a non-acceptable coupling point between the two load paths.
[0064] Furthermore, the invention offers a possibility for the uninterrupted monitoring of the entire load path. Dormant faults can be excluded, and the monitoring system can localize and identify the fault.
[0065] The illustrated exemplary embodiment of the flap system also is usable for the realization of the thrust reversal of an aircraft engine without expensive technical modification.
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The invention relates to a flap system for an aircraft high lift system or an engine actuation with a rotary shaft system, one or more drive stations as well as elements for transmitting the drive energy from the rotary shaft system to the one or more drive stations, wherein at least one drive station includes at least two independent load paths with at least one rotational transmission each for actuating the flap kinematics, and per load path at least one mechanically coupling-free synchronization unit is provided for compensating regular load fluctuations between the load paths. The invention furthermore relates to a method for monitoring a flap system with at least two redundant load paths which each comprise at least one rotational transmission, wherein it is cyclically checked whether the difference of the output-side torques of the at least two load paths exceeds a defined threshold value and/or lies within a defined limit range.
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FIELD OF THE INVENTION
This invention relates generally to a false twist crimping machine for processing synthetic yarn and in which a yarn supply creel extends parallel to and is spaced from the central frame to provide a service aisle between the creel and the central frame, and more particularly to an improved thermal treatment zone extending above the service aisle and defining a roof-like structure to provide effective and reliable contact of the advancing yarn with the heating and cooling plates so as to permit increased operating speeds without increasing the machine height.
BACKGROUND OF THE INVENTION
It is generally known to provide a yarn supply creel extending in spaced parallel relationship along a false twist crimping machine to define a service aisle between the creel and the central frame of the machine. It is also known to direct the yarns from the yarn supply packages on the creel and along a path of travel above the service aisle while directing the yarns over yarn heating and cooling plates with the yarn heating and/or cooling plates forming a roof-shaped structure so that the thermal treatment zone is lengthened for the purpose of increasing the yarn processing speed without unduly increasing the machine height. False twist crimping machines of this general type are disclosed in U.S. Pat. Nos. 4,141,206, 4,058,961, and 4,572,458.
The thermal treatment zones extending across the service aisles, as disclosed in these prior art patents, do not provide an adequate length for the heating and cooling of the yarn in order to further increase the yarn processing speeds to more than 1,200 meters per minute. In order to be able to increase the operating speeds to this level, it has been found that an adequate length of the thermal treatment zone can be achieved only when a reliable contact of the advancing yarn with the yarn heating plate and the yarn cooling plate is insured.
SUMMARY OF THE INVENTION
With the foregoing in mind, it is an object of the present invention to provide an improved thermal treatment zone in which the configuration and the positioning of the yarn heating plate and the yarn cooling plate have the longest possible effective contact length while maintaining substantially the same overall height of the machine.
In a preferred embodiment of the present invention, a yarn false twist crimping machine is provided which comprises a central frame, and a side frame laterally spaced from the central frame and defining a service aisle therebetween. The side frame is adapted for mounting yarn bobbins thereon, and a first yarn feeding means is mounted to the side frame. Yarn heating means is positioned adjacent the side frame and below the first yarn feeding means, and the heating means includes a downwardly directed guideway having an inlet end for receiving the yarn from the first yarn feeding means, and an outlet end. A deflecting yarn guide is positioned adjacent the outlet end, and an upwardly directed guideway is provided which has an inlet end adjacent the deflecting yarn guideway, and an outlet end. Also, yarn cooling means is provided which has an inlet end adjacent the outlet end of the upwardly directed guideway, and with the yarn cooling means extending across and above the service aisle. Yarn false twisting means is mounted to the central frame for receiving yarn from the outlet end of the yarn cooling means, and winding means is mounted to the central frame for winding the processed yarn.
In the above described embodiment, the overall length of the yarn heating means is shorter than the known types of yarn heating means. Specifically, in this arrangement the yarn heating means is provided with downwardly and upwardly directed yarn guideways so that the effective contact length of the heater is increased and the upper end of the yarn heating means does not extend substantially above the height of the creel so that a sufficient space is left for positioning the yarn cooling means above the service aisle.
The yarn cooling means is preferably in the form of one or more elongate plates. For example, the cooling means may comprise one elongate plate, which extends across and above the service aisle along a continuously curved path in the general shape of a cupola when viewed in cross section. In a further embodiment, the cooling means may be two plates which extend over the service aisle in the shape of a continuous curve, and the yarn guideways in each cooling plate may face away from the service aisle. In this arrangement, it is not absolutely necessary that the curvature be constant over the length of the yarn cooling means. Rather, it may be useful for the purpose of influencing the yarn tension in various areas of the yarn cooling means, to increase the curvature, especially in the exit area. This configuration provides that the yarn tension and force at which the yarn initially contacts the cooling means are substantially reduced to provide protection for the hot yarn.
It is also possible to make the cooling means in the form of upwardly inclined and downwardly inclined plates defining a peaked roof-like structure which extends across and above the service aisle. When the yarn guideway of at least one of the yarn cooling sections faces away from the service aisle and is concavely curved relative to the service aisle, the increased curvature minimizes the looping of the yarn about the deflecting yarn guide which is positioned between the two sections. A further reduction of the overall length of the yarn heating plate is also made possible in that the yarn heating plate is more curved than before, for example, with a radius of curvature of less than ten meters.
Another object of the present invention is to redjuce both the stress on the yarn and the twist stop effect at the yarn deflection points, while maintaining the necessary length of the thermal treatment zones. This is accomplished in an embodiment of the invention wherein the yarn heating plate and the yarn cooling plate are configured over the service aisle preferably in the shape of a curved roof or a cupola, and so that at least the yarn cooling plate forms an upwardly vaulted curve. In this arrangement, the yarn heating plate may be arranged to rise substantially vertically from the yarn supply creel and the concavely curved yarn cooling plate may extend substantially downwardly, starting approximately at the height of the end of the yarn heating plate, and both may extend over the service aisle in the shape of a curved roof.
The yarn heating plate and/or the yarn cooling plates have an outwardly and upwardly curved concave shape when viewed from the service aisle and jointly extend over the service aisle in the shape of a curved roof. To facilitate the periodically necessary maintenance work in cleaning the yarn guideways, the outwardly curved cooling plate and/or the outwardly curved yarn heating plate may be supported for pivotal movement in the plane of the yarn path about pivot points positioned in the end areas of the plates.
An advantageous arrangement is provided particularly for high yarn speeds in which the yarn heating plate is arranged upright and adjacent the yarn supply creel and wherein the yarn cooling plate include two sections. The yarn cooling plate sections extend over the service aisle substantially in the shape of a curved roof and are interconnected by a yarn deflector. At least one of the two sections may be convex. To facilitate the necessary maintenance work, each convexly shaped yarn cooling plate section is supported for rotation in the plane of the yarn path and about an axis located in the area of its upper end.
In a further embodiment of the false twist crimping machine of the present invention, the yarn heating plate is arranged on or adjacent to the yarn supply creel and substantially rises therefrom, being preferably curved inwardly toward the service aisle. Advantageously, the inlet end of the yarn cooling plate is located substantially in the vicinity of and aligned with the outlet end of the yarn heating plate. The yarn cooling plate extends in an outwardly vaulted curve from the exit end of the yarn heating plate to the central frame of the machine substantially in the area of the false twisting unit. A particularly favorable arrangement results when the inlet end of the yarn cooling plate is so disposed that it is substantially aligned with the outlet end of the yarn heater plate so that the yarn advances from the yarn heater plate to the yarn cooling plate and from the yarn cooling plate to the false twist unit without a deflection except for that resulting from the curvature of the yarn cooling plate. If the outlet end of the yarn cooling plate is so arranged that it is substantially aligned with the yarn path into the false twist unit, the yarn will also advance from the yarn cooling plate into the false twist unit without a deflection. In this manner, it is insured that a smooth passage of the yarn occurs from the yarn cooling plate to the false twist unit.
The necessary maintenance work may be facilitated by forming the cooling plate in a pair of substantially equally long sections which are aligned with each other as precisely as possible at their common separating point. At least one section, and preferably both sections, are supported for rotation in the yarn path plane about pivot points provided on their lower ends.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the present invention will appear as the description proceeds when taken in connection with the accompanying drawings, in which--
FIG. 1 is a cross-sectional view of one-half of a false twist crimping machine and illustrating one embodiment of the thermal treatment apparatus of the present invention;
FIG. 2 is an enlarged fragmentary elevational view of the yarn heating means supported adjacent the creel in FIG. 1, and taken in the direction of the arrow II;
FIG. 3 is a view similar to FIG. 1 but illustrating another embodiment of the thermal treatment apparatus in accordance with the present invention;
FIG. 4 is a view similar to FIG. 1 but showing another embodiment of the thermal treatment apparatus of the present invention;
FIG. 5 is a view similar to FIG. 1 but illustrating yet another embodiment of the thermal treatment apparatus, and wherein the cooling plate extends over the service aisle in the shape of a cupola;
FIG. 6 is a somewhat schematic view of an arrangement of the yarn heating and cooling plates providing very little overall deflection of the yarn path passing over the yarn heating plate, the yarn cooling plate, and into the false twist unit; and
FIG. 7 is a view similar to FIG. 1 but illustrating still another embodiment of the thermal treatment zone with an ascending yarn heating plate and a substantially descending yarn cooling plate.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The embodiment of the yarn false twist crimping machine illustrated in cross section in FIG. 1 includes a central machine frame 1 which is cut longitudinally along a central plane of symmetry, indicated by the dash-dot line 19. All machine parts described on this half of the machine frame are also present in a mirror-inverted manner on the other side of the plane of symmetry 19. The machine central frame 1 has a longitudinal front which extends parallel to the plane of symmetry 19. Distributed in spaced-apart relationship along this longitudinal front are adjacent yarn processing stations including parts to be described, with all of the spaced-apart yarn processing stations corresponding to the cross-sectional plane illustrated in FIG. 1. The crimping machine also includes a side frame 5 which extends in parallel relationship and laterally spaced from the longitudinal machine front to provide a service aisle 18 therebetween. The side frame 5 includes a yarn creel 2 which is illustrated as an elongate frame in FIG. 1, but it is to be understood that the creel may be in the form of individual, tower-like rotatable frames, such as disclosed in U.S. Pat. No. 4,572,458.
A number of yarn take-off supply packages 3 are supported on the creel 2 and from which the yarns to be processed are unwound. The yarn, indicated at 4, unwinds from each supply package 3 and passes through suitable yarn guides to an additional yarn deflecting yarn guide 15. The withdrawn yarns 4 are spaced apart in the longitudinal direction of the machine as they are drawn upwardly so that they advance at spaced-apart parallel distances relative to each other. While the path of only one individual yarn 4 is described, it is to be understood that the same description also applies to the other yarns.
From the deflecting yarn guide 15, each yarn 4 passes through a first yarn feed device 6. The device 6 is supported on the upper portion of the supporting side frame 5, which is positioned at one side of the service aisle 18 as noted above. A motor 6a (FIG. 2) drives the first yarn feed device 6 at a constant speed. The yarn 4 passes around the first yarn feed device 6 and is pressed thereagainst by a nipping apron 20 so that the yarn extends approximately 90 degrees around and over the first yarn feed device 6. Such a yarn feed device 6 is conventional and is disclosed, for example, in British Pat. No. 1,414,276.
The yarn 4 then contacts a yarn heating means 7 supported on the support frame 5. As best seen in FIG. 2, the yarn heating means 7 is positioned below the first yarn feeding device 6 and comprises a downwardly directed plate or guideway 7a having an upper inlet end adjacent the feeding device 6 for receiving the yarn, and a lower outlet end. The yarn heating means 7 also includes a deflecting yarn guide 16 adjacent the lower outlet end of the guideway 7a, and an upwardly directed plate or guideway 7b having an inlet end adjacent the guide 16. Thus the yarn advancing from the yarn feed device 6 is first guided downwardly and along the yarn guideway 7a, then deflected by 180 degrees passing beneath the yarn guide 16, and then again guided upwardly along the second yarn guideway 7b. By this arrangement, the effective heating length along the yarn path corresponds to twice the height of the yarn heating means 7. The yarn heating means 7 thus includes two elongated, metallic yarn contact surfaces or guideways which are parallel to each other and preferably curved inwardly, as indicated in FIG. 1. The radii of the curvature of the yarn guideways is preferably relatively small, for example, about ten meters or less, and most preferably, about seven meters or less. The yarn heating means 7 may also be in the form of a hollow metal box, on the surface of which the hot plates are formed with yarn guideways. Alternatively, metal plates may be clamped on the box. The hollow box may be filled with a fluid, for example, water, biphenyl (Dowtherm), which is heated and the vapors of which transfer their vaporiztion heat to the cold places of the wall and condense in so doing. Such heating systems are disclosed, for example, in U.S. Pat. No. 4,001,548.
The yarn 4 is deflected at about 60 degrees obliquely upwardly at the outlet end of the yarn heating means 7 by a defecting yarn guide 17. The yarn 4 then moves into contact with the inlet end of a yarn cooling means which includes an upwardly inclined first portion or section 13 and a downwardly inclined second portion or section 14. Each section of the yarn cooling means is preferably a metal plate which is cooled by recirculated air and provided with a suitable yarn guide groove. The upper end portions of both sections 13 and 14 are interconnected by a yarn deflecting guide 21. Both sections 13 and 14 are inwardly curved with the radius of curvature preferably being short and measuring, for example, about 8 meters or less.
Adjacent the outlet end of the cooling plate section 14, the yarn 4 passes over a deflecting yarn guide 22 and into a false twist unit 8. The yarn 4 then advances to a second yarn feed device 9 with the yarn guide 22 and the false twist unit 8 being located in substantial alignment below the second deflecting yarn guide 22 on the machine frame 1. A second yarn heating box 10 may be arranged below the second yarn feed device 9 and is illustrated as including a plurality of tubes 23 extending therethrough. The yarn 4 is guided through the tube 23 which is heated on its exterior. To this end, the heating box 10 may also be closed and partially filled with a fluid which is heated and transfers its vaporization heat to the tubes 23. Below the tube 23, the yarn 4 is again deflected toward the machine front to a third yarn feed device 11. It is to be understood that the heating box 10 and the third feed system 11 may be eliminated or bypasses, which is done in the production of highly elastic yarns. In any event, each yarn 4 is finally wound on one of the take-up systems 12. Each take-up system 12 is schematically illustrated and comprises, as is well known, a drive roll 24, which is driven at a constant circumferential speed, a traversing yarn guide system, not shown, and a take-up package arm 25 which is provided to pivotally support the take-up package 12 in circumferential contact with the drive roll 24. A buggy 26 may be provided and moved along the service aisle 18 so that an operator may step up on it for threading the yarn and cleaning the contact surfaces or yarn guide grooves of the yarn cooling plates 13, 14.
The embodiment illustrated in FIG. 1 provides an improved thermal treatment apparatus including a yarn heating means 7 and a yarn cooling means provided by upwardly and downwardly extending yarn cooling plate sections 13, 14. In order to obtain a greater yarn heating length, the yarn 4 is reciprocated or passed downwardly and then upwardly along the yarn guideways 7a and 7b on the yarn heating means 7. In order to obtain a greater yarn cooling length, the cooling plate sections 13, 14 extend over the service aisle 18 in a peaked roof-like manner. Also, the inwardly curved cooling plate sections 13, 14 insure a reliable and effective contact of the advancing yarn with the cooling plates sections 13, 14.
The parts of the embodiment of FIG. 3 correspond to the parts of the embodiment of FIG. 1 and bear like reference characters. However, it should be noted that the two sections 13, 14 of the cooling means in the embodiment of FIG. 1 are curved inwardly in a convex manner relative to the service aisle 18 and the yarn guideways face inwardly toward the service aisle. This arrangement has the advantage that the operator can see the yarn guideways from the operating aisle, can thread the yarn from this side and can clean the yarn guideways from the service aisle. On the other hand, this arrangement has a disadvantage in that the yarn is deflected at the deflecting point 21 at a very sharp or large angle so that a high yarn friction can develop at this deflecting point 21. The looping angles of the yarn on each section 13, 14 of the cooling means provide a high total looping angle at which the yarn has to pass over the deflecting yarn guide 21, which angle is much greater than if the cooling plate sections 13, 14 were straight.
In the embodiment of FIG. 3, the cooling plate section 14 is outwardly or concavely curved relative to the service aisle 18 and the yarn guideway or groove faces away from the service aisle 18. While this arrangement is a disadvantage to the operator, the angle of deflection of the yarn on the yarn guides 21 and 22 is smaller in FIG. 3 than the corresponding angle of deflection in FIG. 1. Since the yarn cooling plate section 14 is bowed or curved outwardly, the overall looping angle on the deflecting yarn guides 21 and 22, and on the cooling plate section 14 is somewhat less than the overall looping angle would be if the yarn were guided in a straight line between the deflecting yarn guides 21 and 22.
It is to be understood that the first cooling section 13 of the cooling means could also be arranged to curve outwardly so as to further reduce the looping angle of the yarn on the deflecting yarn guides 17 and 21. The false twist unit 8 can be of any suitable construction and examples of false twist units are disclosed in U.S. Pat. Nos. 3,813,868 and 4,389,841.
In both the embodiments of FIG. 1 and FIG. 3, it is to be understood that the cooling plate sections 13, 14 may be of different or of the same length. The angle between the cooling plate sections 13, 14 may be obtuse with a relatively short cooling length and may be acute, as illustrated, with a greater cooling length. In any event, it is significant that the two sections 13, 14 extend over the service aisle 18 in a two-sided arrangement in the manner of a peaked roof.
Many of the parts of the embodiment of FIG. 4 are identical to corresponding parts of the embodiments of FIGS. 1 and 3 and the same reference characters will be applied to the corresponding parts. In FIG. 4, the cooling plate sections 13, 14 are joined together at their upper free ends, as indicated at 31, to provide one single piece which is arcuately and outwardly curved. The yarn guide grooves face the outside and away from the service aisle 18. The curvature is so selected that the cooling plate sections 13, 14 extend over the service aisle in the shape of a vault or cupola with the curvature of the cooling plate section 13 being less in the area of the yarn inlet than in the area of the cooling plate section 14 at the yarn outlet. This curvature results in the yarn tension being considerably reduced in the inlet area, in which the yarn is still warm or hot, and also the usual tension force at which the yarn contacts the cooling plate section 13 is decreased. The radii of the cooling plate sections 13 and 14 should be less than six times their length, and preferably are less than four times their length.
FIG. 5 illustrates a configuration of the yarn heating means 7 and the cooling plate sections 13, 14 which is particularly advantageous for use in high speed yarn processing. In this embodiment, the first yarn feeding device 6 is positioned and supported closely adjacent the lower end of the yarn supply creel 2 and the yarn heating means is in the form of an elongate plate 7 which extends upwardly with a curvature directed inwardly toward the service aisle 18.. The outlet end 28 of the yarn heating plate 7 is spaced slightly apart from the inlet end 27 of the cooling plate section 13. It is preferred that the heating plate outlet end 28 be aligned with the inlet end 27 of the yarn cooling plate section 13 so that the yarn 4 is not deflected as it advances from the yarn heating plate 7 to the cooling plate section 13. As noted, the yarn guide groove in the yarn heating plate 7 faces inwardly toward the service aisle 18. The cooling plate section 13 continues to extend arcuately upwardly and then across the service aisle 18 and the joined cooling plate section 14 continues to curve downwardly to a point immediately in advance of the false twist unit 8 supported on the machine front. In this arrangement, the outlet end 29 of the cooling plate section 14 is preferably so aligned that the direction of the yarn path into the false twist unit 8 is tangent to the outlet end 29 of the cooling plate section 14. In both the cooling plate sections 13, 14 of FIG. 5, the yarn guide grooves face outwardly or away from the service aisle 18. Also, the radii of curvature of the sections 13, 14 should be less than six times their length, and preferably less than four times their length.
While the outwardly and upward curvature of the cooling plates 13, 14 of FIGS. 4 and 5 has considerable advantages for the yarn guidance, this arrangement may complicate their maintenance. To facilitate maintenance of the yarn cooling sections 13, 14, the lower end portions of the yarn cooling sections 13, 14 are supported on pivot pins, as illustrated at 30, so that the upper end portions of the yarn cooling plates 13, 14 can be lowered into the service aisle for cleaning and the like. When in the operating position, as shown in FIGS. 4 and 5, the adjacent ends of the cooling plate sections 13, 14 abut each other, as illustrated by the separating point 31, which is illustrated as being positioned at the approximate center or at the highest point of the arc described by the cooling plate sections 13, 14.
Another embodiment of the htermal treatment zone is schematically illustrated in FIG. 6 wherein yarn deflection means in the form of two deflectors 21 is positioned above the first yarn feeding means 6. The inlet end of the yarn heating plate 7 is adjacent the deflectors 21, and the outlet end 28 of the yarn heating plate 7 is aligned with the inlet end 27 of the yarn cooling plate 13 so that a very small overall deflection of the yarn takes place as the yarn 4 passes along the yarn heating plate 7 and the yarn cooling plate 13 and around the guide 22 to be fed into the false twist unit 8. More particularly, the yarn heating plate 7 and the yarn cooling plate 13 are generally aligned along a straight line extending between the deflectors 21 and a position immediately above the false twist unit 8. The yarn heating plate is inwardly curved along its length and includes a yarn guideway along its inner surface. The cooling plate 13 is outwardly curved along its length and includes a yarn guideway along its outer surface.
In FIG. 6, the yarn 4 advances from the first feed device 6 upwardly to the highest point of the yarn path where it is deflected over two yarn deflectors 21 onto the yarn guideway of the yarn heating plate 7. Since the yarn 4 is still unheated at this point and a return of the false twist beyond the heater plate entrance is not necessary because the tension in the yarn 4 has practically the lowest value, which occurs along the false twist path between the feed systems 6 and 9, the relatively great deflectdion on the deflecting guides 21 does not provide a substantial disadvantage. During the false twist travel along the path with the yarn in contact with the yarn heating plate 7 and the yarn cooling plate 13, the deflection is very small and practically depends only on the extent of the curvature of the yarn heating plate and the yarn cooling plate 13. A last deflection of the yarn 4 leaving the yarn cooling plate 13 occurs prior to its entry into the false twist unit 8 and on the yarn guide 22, which deflects the yarn 4 to the central rotational axis of the false twist unit 8. To facilitate cleaning of the upwardly curved contact surface of the cooling plate 13, which faces away from the service aisle 18, the cooling plate 13 can be pivoted adjacent its opposite ends on pivot axes 30' extending parallel to the longitudinal yarn path along the cooling plate 13, so that the contact surface or yarn guideway may be easily reached from the service aisle 18.
In the embodiment of FIG. 7, the yarn feeding means is positioned adjacent the upper portion of the side frame, and the yarn heating plate 7 extends arcuately upwardly to a mid-point above the service aisle. both the yarn heating plate 7 and the yarn cooling plate 13 have an outwardly and upwardly curved shape when viewed from the service aisle 18. The radius of the heater plate 7 of this embodiment should be between twenty and five meters, and preferably ten plus or minus two meters. The radius of the cooling plate 13 should be less than six times its length, and preferably less than four times its length. In this arrangement, the outlet end 28 of the yarn heating plate 7 and the inlet end 27 of the yarn cooling plate 13 are aligned with each other at the mid-point above the aisle. Also, the yarn 4 advances without deflection from the yarn heating plate 7 to the yarn cooling plate 13, which both together extend over the service aisle 18 substantially in the form of a curved roof. To facilitate the periodically necessary maintenance work, the outwardly curved yarn heater plate 7 and the outwardly curved yarn cooling plate 13 may be supported for rotation in the plane of the yarn path about an axis, not shown, which is provided in the upper ends of the yarn heating plate 7 and the yarn cooling plate 13 so that the outwardly facing yarn guideways can be easily reached from the service aisle 18.
In the drawings and specifications there has been set forth the best modes presently contemplated for the practice of the present invention, and although specific terms are employed, they are used in a generic and descriptive sense only and not for purposes of limitation, the scope of the invention being defined in the claims.
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A false twist crimping machine is disclosed which is adapted for processing synthetic yarn, and which includes a novel means for the thermal treatment of a yarn at high processing speeds of 1,200 meters per minute and above, and without increasing the overall size of the machine. The yarn thermal treatment means includes a yarn heating plate and a yarn cooling plate. The yarn heating and cooling plates preferably each include a curved yarn path guideway to provide efficient and reliable yarn contact of the advancing yarn with the curved guiding surfaces, and at least the yarn cooling plate extends above a service aisle provided between the central frame of the false twist crimping machine and a yarn supply creel spaced from and extending parallel to the central frame. In one preferred embodiment, the yarn heating plate comprises two side-by-side vertically directed sections which are positioned near the floor next to the creel, with the yarn being guided serially along the two sections and then upwardly to the cooling plate which extends across and above the service aisle.
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This application claims the benefit of German application number 101 26 734.7, filed May 31, 2001, currently pending, the disclosure of which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
The invention relates to a process for wiring electrical contact sites, in particular on the surface of an electronic or microelectronic component.
BACKGROUND OF THE INVENTION
With the trend toward designing semiconductor elements, such as ICs and LSIs, in a highly integrated form and in very small sizes and also for high-speed processes, in recent years the conductors formed on the printed circuit board for mounting the component have been made very fine, creating an extremely dense system of lines, in particular in the edge region. These systems require compact attachment of the component on the printed circuit board. In many technical applications, what is known as the flip-chip technique is used as a basis for establishing contacts of components or chips on the printed circuit board, for example in the production of chip cards, to connect the electrodes of the component directly to the lines of the printed circuit board.
However, on account of the small-sized systems, the electrical contact sites are spaced so close together that the electrical contact sites cannot be transferred onto the printed circuit board in the flip-chip process in a way that is certain to maintain contact.
Consequently, wiring of the original electrical contact sites is necessary to increase the distances between the individual contact sites.
The applicant knows of processes in which a number of components on a common wafer are wired simultaneously.
For example, it has previously been the practice to arrange a metal layer on a patterned insulating layer of an electronic or microelectronic component in such a way that firstly a thin metal layer is applied to the dielectric by means of a vacuum process. After covering with photoresist and patterning of the latter by means of photolithography, the metal layer is chemically or electrochemically reinforced, the resist is subsequently stripped and the first thin metal layer is etched back.
This process is complex and expensive. What is more, the stripping of the resist can lead to particle formation and, accordingly, to a reduction in yield.
Furthermore, the applicant knows of processes in which a metal layer is currentlessly deposited on a patterned dielectric.
However, the metallization created by this process has only small thicknesses. Consequently, it is suitable only for wiring components in cases where the connections of the component are supplied with only moderate current densities.
It is therefore the object of the present invention to provide a process which wires electrical contact sites on the surface of an electronic or microelectronic component with little time expended, in a simple way and with relatively low costs, the metal wiring interconnects being able to carry relatively great current densities.
This object is achieved according to the invention by the process with the features specified in patent claim 1 .
SUMMARY OF THE INVENTION
The present invention provides a process for wiring electrical contact sites on the surface of an electronic or microelectronic component, with the following steps: applying and patterning at least one dielectric on the component surface; currentlessly depositing a conductor starting layer on a corresponding patterned layer that has been provided and can be metallized, for producing metal wiring interconnects and substitute contact sites with short-circuit contacts for interconnecting the individual metal wiring interconnects and consequently the electrical contact sites; reinforcing the conductor starting layer by a common electrodepositing process; and separating the short-circuit contacts for separating the individual electrical contact sites from one another.
The process according to the invention offers the advantage that the metal wiring interconnects created have a greater thickness in a shorter time and can consequently carry a greater current density.
Moreover, the metallization process can be carried out simply and quickly, since all the electrical connections are short-circuited with one another, allowing a uniform and common electrodepositing process to be carried out.
Advantageous developments and improvements of the process specified in claim 1 can be found in the subclaims.
According to a preferred development, a number of components on a common wafer are wired simultaneously. This considerably reduces the expenditure on producing the individual components and reduces the production costs.
According to a further preferred development, the short-circuit contacts for the connection of the individual electrical contact sites are arranged in isolation trenches at the peripheral edge of the individual components. When the individual components are separated, for example by sawing along the isolation trenches, the short-circuit contacts are consequently also automatically separated, saving a step in the process and reducing the amount of work involved.
According to a further preferred development, the short-circuit contacts are realized by means of a ground plane in connection with electro and/or laser fuses. This is a possibility for simple separation of the short-circuit contacts at the end of the production process for the case in which the short-circuit contacts are not arranged in the isolation trenches.
According to a further preferred development, the component surface is formed as a non-metallizable substrate. In the case of a metallizable substrate, the dielectric is applied to the substrate as a non-metallizable dielectric in the form of a mask. For example, a non-metallizable layer, preferably a monomolecular layer, is applied by introducing it into a masking solution.
According to a further preferred development, the dielectric is formed as a metallizable dielectric or metallizable buffer layer, for example of polybenzoxazole, polyimide, siloxane-based polymers or polymers of acrylonitrile butadiene styrene.
According to a further preferred development, the component surface is formed as a metallizable substrate, the dielectric in this case being applied to the substrate as a non-metallizable dielectric patterned in the form of a mask or unpatterned in a finite layer thickness. This is the negative image of the previously described metallizable dielectric. The non-metallizable layer may also be formed as a monomolecular layer or as a self-organized monolayer.
According to a further preferred development, the conductor starting layer is electrolessly deposited by means of, in particular, a nickel and/or copper electrolyte. This represents a simple way of producing the conductor starting layer.
According to a further preferred development, the conductor starting layer is reinforced [lacuna] copper layer applied by means of an electrodepositing process, in particular a standard or tampon electrodepositing process.
Preferred embodiments of the process according to the invention are described below with reference to the accompanying figures, to explain features essential for the invention.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
In the figures:
FIG. 1 shows a schematic representation of a finished wiring of an electronic or microelectronic component;
FIG. 2 shows a schematic representation of a wiring arrangement during the process according to an exemplary embodiment of the present invention; and
FIG. 3 shows a schematic representation of a wiring arrangement during the process according to a further exemplary embodiment of the present invention.
In the figures, the same reference numerals designate components which are the same or functionally the same.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
On the basis of FIG. 1 , the wiring principle is firstly to be explained. On the surface 2 of a component 1 arranged together with other components on a wafer, predetermined electrical contact sites or pads 3 are initially provided. As already explained above, these are spaced too close together for the flip-chip technique, so that stable electrical contacting is not ensured. Consequently, metal wiring interconnects 6 are respectively created from the individual electrical contact sites 3 to substitute contact sites 7 distributed on the entire surface 2 of the component 1 . These are then at the requisite distance from one another and have the required contact size.
FIG. 2 illustrates a schematic representation of a component during a wiring process according to an exemplary embodiment of the present invention, which is described in more detail below.
Firstly, an electrolessly metallizable dielectric 4 is applied—for example printed on in a way known per se—to the surface 2 of the component 1 , i.e. to the substrate 2 , said dielectric advantageously having the patterning that is shaded dark in FIG. 2 (except for the contact sites 3 ).
This patterning ensures that all the metal wiring interconnects 6 or substitute contact sites 7 are electrically connected to one another via short-circuit contacts 8 . The short-circuit contacts 8 are advantageously arranged in isolation trenches 9 , which represent the delimitations of the individual components 1 from one another on the common wafer.
Next, a conductor starting layer 5 is currentlessly deposited on the metallizable dielectric 2 . For example, after rinsing with deionized water, for this purpose the arrangement is immersed in a heated commercially available ionogenic palladium solution for a certain period of time for seeding the dielectric with a noble metal. Subsequently, reducing is carried out for a certain immersion time, for example with an alkaline sodium borohydride solution. Lastly, a homogeneous copper or nickel layer 5 with good adhesion properties is obtained on the dielectric by immersion in a chemical copper or nickel bath. This conductor starting layer 5 is applied completely homogeneously to the dielectric and consequently constitutes the same structure of the dielectric 4 represented in FIG. 2 .
As the next step, the conductor starting layer 5 is uniformly reinforced by means of an electrodepositing process, in particular a standard or tampon electrodepositing process. Since, as can be seen in FIG. 2 , all the electrical contact sites 3 , metal wiring interconnects 6 and substitute contact sites 7 are electrically connected to one another, a single electrical connection contact is sufficient for the electrodepositing process.
Over the isolation trenches 9 connecting the individual components 1 of the wafer, even a single electrical connection contact is sufficient for the electro-depositing process of all the components 1 located on a wafer. As a result, a number of components on a wafer are simultaneously wired in a simple manner with such a thickness that great current densities can be carried by the corresponding lines.
In particular, the complete wafer can preferably be electrically contacted from the rear side for the electrodepositing, since normally a PIN of the chip has direct contact with the substrate.
In the case of a metallizable substrate 2 , for example formed from polybenzoxazole, polyimide, polybenzimidazole and copolymers of this compound, siloxane-based polymers or polymers of acrylonitrile butadiene styrene, it can be introduced into a corresponding masking solution known per se, whereby a non-metallizable layer is applied to said substrate. Likewise, a printing process may be used for this purpose. This non-metallizable layer is advantageously a monomolecular layer or dielectric with a finite layer thickness. After applying this monomolecular non-metallizable layer, the process described above can be analogously applied.
The reinforcement by electrodeposition described above is completed in a few minutes and simply requires a conductive surface, which is ensured by the electrical interconnection of all the metal wiring interconnects.
The original electrical contact sites 3 located on the substrate 2 , preferably aluminum pads 3 or pads of other suitable materials, are preserved during the electroless deposition of the conductor starting layer 5 as a result of the pH of the copper or nickel bath. Furthermore, a nickel or copper layer, for example, may simultaneously serve as a diffusion barrier for the copper or nickel reinforcing layer subsequently applied over it.
As the next step, the individual 1 components located on a wafer are separated along the isolation trenches 9 , for example by means of sawing. This separation simultaneously brings about a separation of each electrical contact site 3 or the assigned metal wiring interconnects 6 from one another. This allows an additional step in the process after the joint electrodeposition to be saved—the separating of the metal interconnects 6 connected to one another for the electrodeposition.
It is likewise conceivable as a further exemplary embodiment that the component surface 2 is formed as a metallizable substrate 2 . In the case of this exemplary embodiment, a non-metallizable layer may be applied over the full surface area of the metallizable substrate 2 and the same procedure followed as in the process described above according to the first exemplary embodiment.
Furthermore, a non-metallizable mask, preferably a monomolecular layer or a dielectric with a finite layer thickness, and having the structure represented in white in FIG. 2 , may also be applied to the substrate. This corresponds to the negative of the shaded structure represented in FIG. 2 , with an initially non-metallizable dielectric.
The then still exposed regions of the currentlessly metallizable substrate 2 are metallized in a way analogous to the process described above and reinforced by an electrodepositing process.
A monomolecular layer, known as a self-assembled monolayer, of an appropriate substance which prevents metallization of a correspondingly covered region is likewise adequate for the masking.
FIG. 3 shows a schematic representation of a further exemplary embodiment of a wiring process.
According to this exemplary embodiment, the short-circuit contacts 8 are accomplished in the course of the process by means of ground planes 11 in connection with electro and/or laser fuses 12 . This likewise permits a continuous conductive surface to be achieved in a simple way for the electrodeposition in electrolytic baths.
However, in this case complete separation of the individual metal wiring interconnects 6 does not take place during the separation of the individual components 1 from one another by sawing, for example, along the isolation trenches 9 , since the short-circuit contacts are not arranged on or in the isolation trenches 9 .
Separating of the short-circuit contact takes place in the case of electro fuses in an electrical manner and in the case of laser fuses by means of a laser beam. In both cases, the electrical connection of the individual electrical contact sites 3 and of the substitute contact sites 7 is interrupted for the further use of the component 1 .
Although the present invention has been described above on the basis of preferred exemplary embodiments, it is not restricted to these but can be modified in a variety of ways.
For example, other suitable materials may be used in the individual process steps.
LIST OF REFERENCE NUMERALS
1
component
2
component surface
3
electrical contact sites/pads
4
metallizable dielectric
5
conductor starting layer
6
metal wiring interconnects
7
contact sites of the wiring
8
short-circuit contacts
9
isolation trenches
11
ground planes
12
electro/laser fuses
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The present invention provides a process for wiring electrical contact sites, in particular on the surface of an electronic or microelectronic component, with the following steps: applying and patterning at least one dielectric on the component surface; currentlessly depositing a conductor starting layer for producing metal wiring interconnects and substitute contact sites with short-circuit contacts for interconnecting the individual metal wiring interconnects and the corresponding electrical contact sites; reinforcing the conductor starting layer by a common electrodepositing process; and separating the short-circuit contacts for separating the electrical contact sites or the contact sites of the wiring from one another.
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FIELD AND BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to the field of bras and related garments, and in particular to a new and useful method and pad product having a thicker central summit area for use in bras, camisoles, slips, swimsuits or any other breast covering garment where padding is desired.
[0002] It is known to provide resilient pads in bras to accentuate the figure. Padded bras are not always desirable, however. Bras without pads are also known but these have limited ability to enhance the figure.
[0003] U.S. Pat. No. 4,013,750 discloses a method for making brasserie pad pre-forms which can produce a bra pad having a thicker central region than its outer regions. A mold apparatus is utilized which produces a substantially conical pad of polyester fibers with a summit which is thicker than the periphery of the conical pad. Also see U.S. Pat. No. 3,947,207.
[0004] Other patents of interest to the present invention are:
U.S. Pat. No. Inventor(s) 2,507,543 Prager 2,565,400 Skeoch 2,616,093 Talalay 2,627,368 Jantzen 2,702,769 Alderfer 2,845,974 Ashton et al. 3,164,655 Howard et al. 3,186,271 Kaiser 3,311,007 McGee 3,417,755 Howard et al. 3,464,418 Silverman 3,502,083 Howard et al. 3,800,650 Schroder 4,351,211 Azzolini 5,017,174 Gowrylow 5,299,483 Ber-Fong.
[0005] U.S. Pat. No. 2,627,368 to Jantzen discloses a method of making curved pad filler in which a mold is provided with a concave part for receiving a part of a blank of material. A means are provided for pushing or pressing the blank into the concave part of the mold. A sharp moving knife is passed between the mold and the pressing element, resulting in a curved shoulder pad filler and uniformly tapered portions extending from the thick end to a feathered edge.
[0006] U.S. Pat. No. 3,186,271 to Kaiser discloses an apparatus and method for producing shaped articles consisting of foam such as sponges and cushions.
[0007] Neither the Jantzen nor the Kaiser patents teach or suggest a sheet of material having a pair of thicker areas positioned so that they correspond to the location where the central summit of the bra pad will be when it is completed.
[0008] U.S. Pat. Nos. 3,164,655, 3,417,755 and 3,502,083 to Howard et al. disclose molding of a blank to give it a desired shape and contour but fail to teach or suggest forming a foam sheet of material having a pair of thicker areas positioned so that their position corresponds to the location where the central summit of the bra pad will be when it is completed after thermoforming.
[0009] U.S. Pat. No. 2,616,093 to Talalay discloses an apparel pad such as a shoulder or breast pad, which as a concavo-complex shape with a thickness graduated from a relatively thick portion to a relatively thin portion using different pieces of material to build up the pad.
[0010] U.S. Pat. No. 3,311,007 to McGee discloses an apparatus for producing at least one contoured surface upon a foamed material pad but is very different from the present invention because it teaches the effects of cutting a foam member which is compressed by a male mold portion against an opposite flat mold portion, and thus, the contour of the shaved material is based on the shape of the male mold portion. McGee fails to teach contouring of an article based on a foam material being pressed to cover and penetrate a recess before the foam material is shaved.
[0011] U.S. Pat. No. 2,727,278 to Thompson discloses a method of making a molded composite bra, in which the thickness of filler material in each bra pad has a summit thickness greater than the thickness surrounding the summit. The process for making the molded bra is however very different from the present invention and does not teach shaving a material compressed into a recess.
[0012] The remaining patents disclose other pad-related technology which are distinguishable from the invention, and they are enclosed for general reference.
[0013] A need remains for an improved pad, as well as a method for producing such a bra pad, which adds some padding effect to the bra but in a very subtle manner so that the padding is barely perceptible.
SUMMARY OF THE INVENTION
[0014] It is an object of the present invention to provide a method of manufacturing a bra pad having a thicker central summit area, as well as the pad itself and the apparatus for manufacturing the pad, comprising holding a sheet of uniform thickness, resilient and formable material, such as thermoplastic foam, and forming the sheet to have one or two thicker summit areas corresponding to the summits of the bra or bra-like garment (here called a bra for any garment in which the pads are ultimately used). Each pad thus has a thicker summit area for extending over the summits of the breasts of a wearer of the bra.
[0015] A further object of the invention is to provide the bra pad made in accordance with the method of the invention.
[0016] The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which a preferred embodiment of the invention is illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] In the drawings:
[0018] FIG. 1 is a side elevation view of an open shaving mold used to make the pads and to practice the method of the present invention with a sheet of polyurethane foam material therebetween;
[0019] FIG. 2 is a view similar to FIG. 1 of the shaving mold in its closed position and with a shaving device in an initial position of use;
[0020] FIG. 3 is a view similar to FIG. 2 with the shaving apparatus in a final position;
[0021] FIG. 4 is a side elevational view of a shaved or graduated sheet component of the bra pad in accordance with the present invention;
[0022] FIG. 5 is a view similar to FIG. 4 of an assembled pre-form of the bra pad according to the present invention;
[0023] FIG. 6 is an exploded view of a forming mold with the pre-form bra pad between the mold halves thereof;
[0024] FIG. 7 is a sectional view of a formed component for creating two foam pads of the present invention;
[0025] FIG. 8 is a top plan view of the formed component of FIG. 7 ; and
[0026] FIG. 9 is a view of a pair of bra pads constructed in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] Referring now to the drawings, in which like reference numerals are used to refer to the same or functionally similar elements, FIG. 1 shows a shaving mold generally designated 10 comprising a lower shaving mold portion 12 and an upper shaving mold portion 14 with a thickness of e.g. 7 mm polyurethane foam 16 therebetween. Although polyurethane foam is illustrated, any thermo plastic foam material can be used according to the present invention and in fact any formable material can be used which is resilient and is capable of being formed into a permanent yet resilient three-dimenisonal shape. The shaving mold halves or portions 12 and 14 can be made of wood, plastic, metal or other suitable rigid material. Lower mold half 12 contains a pair of recesses 18 in its upper surface which are positioned so that they are near the central summit of each bra pad to eventually be made in accordance with the present invention.
[0028] FIG. 2 illustrates the shaving mold in its closed position with the resilient formable sheet of material 16 pressed down onto the lower mold half so that some of the material of sheet 16 is pressed into each recess 18 but also a thickness of material, for example at 20 , remains along the shaving mold halves.
[0029] A shaving apparatus generally designated 22 is also illustrated in FIG. 2 which comprises a movable carriage 24 , which carries a blade, knife or shaving member 26 that extends transversely the full width of material sheet 16 (perpendicular to the plane of FIG. 2 ). Blade 26 is also positioned intermediate to the upper and lower shaving mold halves 14 , 20 respectively so that a portion of the layer 20 can be neatly shaved from the sheet 16 . For this purpose, member 26 may be heated (e.g., a cutting wire), may be mounted for movement like a band saw, may be reciprocally vibrated back and forth like an electric knife or oscillated in any other appropriate way for cutting the foam material of sheet 16 .
[0030] With the shaving apparatus 22 activated to vibrate, heat or otherwise activate member 26 , the carriage 24 is moved in the direction of arrow A and across the sheet 16 until it reaches its final position shown in FIG. 3 . In this position a slice 30 has been made in sheet 16 thus achieving the shaving effect. FIG. 4 shows the shaved component or graduated sheet 16 a which is removed from the shaving mold after it is opened and which contains a pair of thicker material areas 17 at a summit e.g. of 5.5 mm thickness, surrounded by thinner material areas 19 , e.g. 1 mm thick. FIG. 8 illustrates in dotted line the two summit areas 17 on the rectangular and graduated sheet 16 a which, in FIG. 8 , has already been attached to as second outer cup sheet 32 , e.g. 2 mm thick, shown in FIG. 5 which is also made of polyurethane foam material. Shaved or graduated sheet 16 a forms an inner cup sheet.
[0031] As shown in FIG. 5 , each of the cup sheets 16 a and 32 may also include a laminate or fabric covering 33 and 34 , respectively, made, for example, of nylon or nylon with spandex. This is a conventional covering for foam pads used in bras. It is important that in accordance with the present invention, the laminate 33 be on the outer inner surface of the inner cup sheet 16 a so that it is not shaved away by the shaving apparatus 22 and that the outer cup sheet 32 have its laminate 34 on its outer surface. This leaves the inner surfaces of panels 16 a and 32 free to receive sprayed on glue. After the glue is sprayed on the two surfaces are pressed against each other to produce the single composite pre-form illustrated in FIG. 5 .
[0032] In FIG. 6 a thermo-forming mold 40 is generally designated 40 and, as illustrated, includes a lower female mold portion or half 42 and an upper mold half or portion 44 . The pre-form 16 a , 32 is positioned between the mold halves 42 , 44 with the summits 17 centered on a pair of recesses 46 formed in the lower female mold half 42 which also correspond with a pair of male projections 48 formed in the male mold half 44 . Each projection 48 may also include a slight recessed or flattened area 49 or an area which is shaped to keep from completely crushing the summit areas 17 of the inner cup sheet 16 a.
[0033] The mold halves are heated to the appropriate level for molding the pre-form into a finished molding illustrated in FIGS. 7 and 8 . The finished molding has thicker summit areas 17 , e.g. 5-6 mm thick, surrounded by the thinner surrounding areas 19 , e.g. 1 mm thick, which completely encircle each summit area 17 and have an inner area of e.g. 2 mm thick, so that a bra manufactured with or containing the bra pads of the present invention will have a slightly thicker area 17 , for example 3 mm, over the summit of each breast summit, and thinner material, e.g. tapering down to 1 mm, in thinner areas 19 .
[0034] FIG. 9 illustrates the pair of pads 52 , 54 which are cut from the molding of FIGS. 7 and 8 and are ready for use in a bra, in a conventional manner. The pads 52 , 54 may also be used in other garments for covering the torso of a woman and which contain bra or bra-like structures such as bathing suits, camisoles, and the like.
[0035] While a specific embodiment of the invention has been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles.
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A method of manufacturing a bra pad having a thicker summit area, as well as the pad itself, includes holding a sheet of resilient and formable material of uniform thickness, such as thermoplastic foam, and forming the sheet to have a graduated thicker summit area corresponding to each summit of a bra or bra-like garment for including the pad, and a surrounding thinner area. Each pad thus has a thicker summit area for extending over the summits of the breasts.
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TECHNOLOGICAL FIELD
[0001] The present disclosure relates generally to firearms. More specifically, it relates to semi-automatic rifles.
BACKGROUND
[0002] Firearms for hunting and sport shooting come in a range of types, such as traditional hunting rifles with wood butt stocks and fore stocks to military type rifles. In the latter group, there is an interest in rifles that have military ruggedness and appearance but meet requirements for ownership and use, such as, for example, a limitation to semi-automatic mode rather than fully-automatic operation. Semi-automatic mode means that the trigger must be released for the next round to be fired. If the trigger is pulled but not released, one round only is fired.
BRIEF SUMMARY
[0003] The present disclosure is of a rifle having the features typical of light machine guns but operates only in semi-automatic mode. For example, it may be fed ammunition using an ammunition belt, its receiver has a pivoting cover to admit the first round of the belt, and it has charging handle similar to those of military machine guns.
[0004] The present rifle has a barrel, a buttstock, a receiver, and a trigger. The barrel has a forward end and an opposing rearward end and may be covered on top and on the bottom by a heat shielding. A breech is formed in the rearward end of the barrel where it is joined to the forward end of the receiver. A buttstock is attached to the rearward end of the receiver. The trigger is held within a trigger housing attached to the underside of the receiver. The trigger housing may also include a pistol grip.
[0005] A feature of the present rifle is that the receiver is configured to receive ammunition from a belt and, according to the preference of the user, from a magazine without modification. It has a magazine well to receive an ammunition magazine and a ramp for belt-fed ammunition with a receiver top cover that pivots open to allow the first round of a belt of ammunition to be put in position for loading into the breech.
[0006] The present rifle includes a bolt, a firing pin carried by the bolt, a sliding hammer, and a spring system for urging the hammer to move forward in the receiver to strike the firing pin. The operation of the bolt seats the next round, extracts the spent cartridge casing after firing, and pulls into position the next round as part of the firing cycle. The trigger assembly includes a trigger, a disconnector that pivots a sear when said trigger is pulled. The sear automatically catches the hammer on recoil and holds it until the disconnector, lifted by the pull of the trigger, again pivots the sear to release the hammer.
[0007] The charging handle is on the right side of the receiver with a forward and rearward position and is used to seat the first round in the breech. The present rifle has a broad heat shield extending over, and a hand guard under, the barrel, and a mid-position carrying handle that adds to the light-machine gun appearance of the present semi-automatic rifle.
[0008] Another feature of the disclosure is that the firing pin is slidably carried within the bolt so that the pin travels with the bolt but also moves with respect to the bolt when the pin is struck by the sliding hammer.
[0009] Another feature of the disclosure is the rails formed on the interior of the receiver housing. The hammer rides on the rails between the forward end of the receiver and the rearward end.
[0010] A feature of the disclosure is a spring that urges the trigger to move against a second pin in the trigger housing, after the trigger returns to the released position, with an audible and tactile click so that the user hears and feels that the trigger has seated in the released position and that, therefore, the trigger is again ready to pull in order to fire another round of ammunition.
[0011] These and other features and their advantages will be apparent to those skilled in the firearm arts from a careful reading of the detailed description of preferred embodiments accompanied by the following drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] In the drawings,
[0013] FIG. 1 is a left side view of the semi-automatic rifle, according to an aspect of the disclosure.
[0014] FIG. 2 is a top view of the semi-automatic rifle, according to an aspect of the disclosure.
[0015] FIG. 3 is a right side view of the semi-automatic rifle, according to an aspect of the disclosure.
[0016] FIG. 4 is a left side, partial cross-sectional, detailed view of the receiver of a semi-automatic rifle, according to an aspect of the disclosure.
[0017] FIG. 5 is a right side, cross-sectional view of a trigger assembly of the semi-automatic rifle, according to an aspect of the disclosure.
[0018] FIG. 6 is a left side, exploded view of the trigger assembly of the semi-automatic rifle, according to an aspect of the disclosure.
[0019] FIG. 7 is a left side perspective view of the bolt of the semi-automatic rifle, according to an aspect of the disclosure.
[0020] FIG. 8 is a top, cross-sectional view of the bolt of the semi-automatic rifle, according to an aspect of the disclosure.
[0021] FIG. 9 is a left side, exterior view of the operating group showing the bolt and operating rod, according to an aspect of the disclosure.
[0022] FIG. 10 is a left side, perspective view of the hammer of the semi-automatic rifle, according to an aspect of the disclosure.
[0023] FIG. 11 is a right side view of the interior of the receiver of the semi-automatic rifle, according to an aspect of the disclosure.
[0024] FIG. 12 is a left side view of the interior of the receiver and part of the barrel of the semi-automatic rifle with the bolt shown in cross-section revealing the hammer on the sear, according to an aspect of the disclosure.
[0025] FIG. 13 is a left side view of the interior of the receiver and part of the barrel of the semi-automatic rifle with the bolt shown in cross-section revealing the hammer moving toward the firing pin, according to an aspect of the disclosure.
[0026] FIG. 14 is a right side view of the interior of the receiver showing the position of the hammer at the moment it strikes the firing pin, according to an aspect of the disclosure.
[0027] FIG. 15 is a left side view of the interior of the receiver showing the hammer at the moment it strikes the firing pin, according to an aspect of the disclosure.
[0028] FIG. 16 is a right side view of the interior of the receiver with the hammer and bolt in the process of recoiling after firing a round, according to an aspect of the disclosure.
[0029] FIG. 17 is a left side view of the interior of the receiver with the hammer and bolt partially recoiled after firing a round, according to an aspect of the disclosure.
[0030] FIG. 18 is a right side view of the interior of the receiver showing the bolt and hammer fully recoiled, according to an aspect of the disclosure.
[0031] FIG. 19 is a left side view of the interior of the receiver showing the bolt and hammer fully recoiled, according to an aspect of the disclosure.
[0032] FIG. 20 is a left side view of the interior of the receiver showing the bolt and hammer returning after recoil and with the hammer now caught by the sear, according to an aspect of the disclosure.
[0033] FIG. 21 is a right side view of the interior of the receiver showing the bolt closing into the barrel and the hammer held by the sear and poised to move forward once the trigger is pulled, according to an aspect of the disclosure.
[0034] FIG. 22 is an end cross sectional view of the receiver, according to an aspect of the disclosure.
DETAILED DESCRIPTION
[0035] In this disclosure, regarding a rifle, the terms proximal and rearward refer to the “butt stock” end of the rifle and forward or distal refer to the “barrel end” of the rifle, generally consistent with the perspective of a user who is holding the rifle in firing position. Similarly, upward and downward are from the perspective of a user standing and holding the firearm in normal orientation, that is, with the trigger oriented to extend toward the earth. The terms left side and right side are from the perspective of someone aiming the rifle. When introducing elements of the present disclosure or exemplary aspects or embodiment(s) thereof, the articles “a,” “an,” “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising,” “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements. Although this disclosure has been described with respect to specific embodiments, the details of these embodiments are not to be construed as limitations.
[0036] As seen in FIGS. 1-3 , the present rifle 10 has a barrel 12 , a receiver 14 , a heat shield 16 , and a hand guard 18 . It also has a carrying handle 20 , a charging handle 22 , and a cover plate 24 . Below receiver 14 is a trigger assembly 26 . Attached to barrel 12 is a bipod 28 . On the proximal end of rifle 10 is a buttstock 30 .
[0037] Rifle 10 is similar in appearance to a military firearm and a light machine gun in particular, because of features such as cover plate 24 , the side-mounted charging handle 22 , a dovetail ramp 32 for accepting a drum of ammunition ( FIG. 1 ), and the barrel heat shield 16 and hand guard 18 . Rifle 10 may receive single rounds of ammunition via a magazine or belt-fed ammunition.
[0038] Although the appearance and many of the features of the present rifle 10 are similar to an M249 machine gun, for example, its firing mechanism is semi-automatic rather than fully automatic, that is, pulling and holding the trigger 34 causes only a single round of ammunition to be fired rather than a continuous series of rounds. Trigger 34 must be released for a second round to be fired. See US publication 2012/0144992 published by Landies, et al, which is incorporated herein in its entirety by reference, for a description of the operation of a conventional M249 machine gun.
[0039] FIG. 4 illustrates a left side view of receiver 14 with part of receiver housing 40 cut away to show some of the individual components of receiver 14 . A round 42 of ammunition is shown seated in the barrel chamber 44 , which is formed in the proximal end of barrel 12 and held in place by the breech face of bolt 48 . A firing pin 46 is poised to fire round 42 as its distal tip is just proximal to the primer carried in the proximal end of the shell casing of round 42 .
[0040] Firing pin 46 is carried inside a bolt 48 , shown in cross-section in FIG. 4 . Bolt 48 is carried in a bolt carrier 52 , which has a slot 138 (seen in FIG. 22 ), formed therein which receives a portion 130 of a sliding hammer 50 , also shown in cross-section in FIG. 4 and in perspective in FIG. 10 , which portion 130 is held in position to strike the proximal end of firing pin 46 . Sliding hammer 50 has pairs of corresponding grooves 124 , 126 , on either side that ride on rails 152 , 154 (seen in FIG. 22 ).
[0041] The movement of bolt 48 and sliding hammer 50 is controlled in part by two springs, an operating group spring 60 and a firing spring 62 . Operating group spring 60 and firing spring 62 are co-axial about an operating rod 56 , which are all seen, at least in part, in FIG. 4 (and also in FIG. 12 , for example). Firing spring 62 , shown in cross-section, has a larger diameter than operating group spring 60 and slows sliding hammer 50 by compressing during the rearward travel of hammer 50 on recoil and then provides the power to drive hammer 50 forward toward bolt 48 and firing pin 46 after being released by sear 70 . Spring 60 also compresses when operating group 58 is driven rearward by the diverted gas acting on the piston 114 , travels rearward and strikes the hydraulic buffer contained in the butt stock assembly and then extends when operating group 59 moves forward to return bolt 48 to its closed position. During its return from recoil, bolt 48 will strip a round 42 from a magazine or belt of ammunition and seat it in the barrel chamber 44 .
[0042] FIGS. 5 and 6 show a right side view and a left side exploded view of trigger assembly 26 . Trigger assembly 26 includes a pistol grip 64 and a trigger guard 66 . Trigger 34 is pulled rearward (to the left in FIG. 5 ) from its normal released position to a pulled position to fire round 42 . When pulled from its released position, trigger 34 lifts a disconnector 68 which pivots the distal end of sear 70 upward. The proximal end of sear 70 then pivots downward about pivot pin 72 which releases sliding hammer 50 from its hammer-catch position to its hammer-release position, as will be described more fully below. A trigger spring 74 resists rearward movement of trigger 34 and urges it forward to its release position. A trigger spring 74 urges sear 70 to return to its hammer-catch position after disconnector 68 pushes it upwardly to its hammer-release position. Accordingly, trigger 34 is spring-biased to its trigger-release position; sear 70 is spring-biased toward its hammer-catch position.
[0043] Upper limit pin 78 limits the upper range of movement of proximal end of sear 70 which is reached when trigger 34 returns to the trigger-release position or disconnector 68 disconnects from sear, which produces an audible and tactile click to alert the user that a round 42 will be fired by the next pull of trigger 34 . Trigger spring 74 seats on trigger spring pin 82 . A safety 84 controls movement of trigger 34 by its axial position, which axial position either blocks or permits movement of trigger 34 . Pistol grip 64 is fastened to trigger assembly 26 by a threaded bolt 86 .
[0044] FIGS. 7 and 8 show bolt 48 in perspective from the right front and in cross-section from the left side, respectively. Bolt 48 holds firing pin 46 which travels with bolt 48 from a distal position locked into barrel 12 to a proximal position toward butt stock 30 . Firing pin 46 also moves through only a limited additional range within, and respect to, bolt 48 when sliding hammer 50 strikes it. When sliding hammer 50 strikes firing pin 46 , firing pin 46 moves forward (to the right in FIG. 7 , to the left in FIG. 8 ). Firing pin 46 is shown in its forward-most position in FIG. 8 . Forward movement of firing pin 46 loads a compression spring 100 that is relieved soon after the impact of sliding hammer 50 as it urges pin 46 rearward.
[0045] Bolt 48 also performs the function of extracting a spent cartridge from barrel chamber 44 using an extractor 102 . Extractor 102 pivots around an extractor pivot pin 106 against the rim of the cartridge, which extractor 102 is biased by an extractor spring 104 against the cartridge rim. Finally, lugs 110 on the distal end of bolt 48 strip a new round 42 from a magazine or ammunition belt and seat it in barrel chamber 44 .
[0046] Bolt 48 also pivots about its own axis as it moves axially. Bolt 48 rides in a bolt carrier 52 , seen in FIG. 9 . A cam follower 108 on bolt 48 extends through a cam race 98 in cam housing 52 that causes bolt 48 to rotate in one direction through part of an arc as bolt travels in one axial direction and then through the same arc in the reverse direction when bolt 48 reverses its axial movement. Bolt carrier 52 travels forward and rearward on rails 118 , 120 (best seen in FIG. 22 ).
[0047] FIG. 9 shows operating group 58 with an operating rod 56 carrying a piston 114 threaded to its distal end and a fitting 116 on its proximal end for attachment to bolt carrier 52 . As operating rod 56 moves forward and rearward, bolt carrier 52 and bolt 48 travel with it, moving rearward on recoil from the closed bolt position, in which bolt 48 is radially unlocked from barrel 12 , and then forward to the closed bolt position again in the next firing cycle. Piston 114 fits into the gas cylinder of rifle that receives a portion of the combustion gas from the firing of round 42 through a hole in barrel 12 which gas drives piston 114 and the balance of operating group 58 rearward.
[0048] FIG. 10 shows sliding hammer 50 with the firing pin-engaging portion 130 extending upward from sliding hammer 50 where it will be received in a slot 138 in bolt carrier 52 (seen best in FIGS. 4 and 22 ). Sliding hammer 50 has an axial hole 132 formed in it for receiving firing spring 60 , recoil spring 62 and operating pin 134 .
[0049] FIGS. 11-21 illustrate relative movements of the present rifle 10 during sequential parts of the firing cycle. FIGS. 11, 14, 16, 18, and 21 show the right side of receiver 14 with housing 40 removed. FIGS. 12, 13, 15, 17, 19, and 20 show the left side of receiver 14 .
[0050] In FIG. 11 shows sliding hammer 50 held by sear 70 urged forward by firing spring 62 with bolt 48 forward in receiver 14 in its closed position radially locked in barrel 12 . Firing spring 62 is compressed, ready to propel sliding hammer 50 forward. Trigger 34 is in its released position. In FIG. 12 , trigger 34 , in its released position, and sear 70 in its hammer catch position so sliding hammer 50 is held in place.
[0051] In FIG. 13 , trigger 34 is in its pulled position, which lifts disconnector 68 that in turn pivots sear 70 so its proximal end rotates up and its distal end rotates down, thereby releasing hammer 50 .
[0052] In FIGS. 14 and 15 , sliding hammer 50 has moved forward far enough so that its engaging portion 130 (see FIGS. 10 and 15 ) has entered slot 138 in proximal end of bolt carrier 48 (see FIGS. 15 and 22 ) and is poised to strike firing pin 46 ( FIG. 15 ). Note that sear 70 has already been reset by the biasing force of sear spring 76 .
[0053] FIGS. 16 and 17 show sliding hammer 50 , now moving rearward toward buffer in butt stock 30 following the firing of round 42 of ammunition. The proximal end of sear 70 is cammed downward by the movement of sliding hammer 50 as it travels rearward but sear 70 immediately resets to its hammer-catch position to catch sliding hammer 50 when it moves forward again. Op group 58 moves rearward with sliding hammer 50 .
[0054] FIGS. 18 and 19 show sliding hammer 50 having reached buffer 136 carried on the distal end of butt stock 30 and which stops rearward movement of sliding hammer 50 . Op group 58 also reaches its rearward-most position with sliding hammer 50 . Sear 70 is set to catch sliding hammer 50 as it rebounds off buffer 136 .
[0055] FIGS. 20 and 21 show sliding hammer 50 , urged by firing spring 62 , moving forward to the point where it is caught by sear 70 , its forward movement halted. Op group 58 , however, continues its forward motion, separating from sliding hammer 50 . Bolt 48 again radially closes on barrel 12 as shown in FIGS. 11 and 12 for the firing cycle to begin again.
[0056] FIG. 22 shows a perspective, cross-sectional view of rifle 10 . Carrying handle 20 is shown in top right, above charging handle 22 . A magazine well 150 is shown on the left. Firing pin 46 is partially obscured by bolt carrier 52 but visible in through slot 138 in bolt carrier 52 . The rear part of the op rod 116 appears below bolt carrier 52 and operating group spring 60 and firing spring 62 are show in it with firing spring 62 being the spring of larger diameter. The top of sear 70 is shown below rear part 116 . Operating group spring 60 and firing spring 62 are also visible through hole 132 of sliding hammer 50 . Sear 70 is shown below hammer 50 .
[0057] Rails 118 , 120 on which bolt carrier 52 rides are seen to its left and right, respectively. Additional rails 152 , 154 , which are received in grooves 124 , 126 of sliding hammer 50 are shown below that on either side of sear 70 .
[0058] Those skilled in firearms will appreciate from the foregoing description of aspects of the disclosure that many substitutions and modifications may be made without departing from the spirit and scope of the disclosed rifle, which is defined by the appended claims.
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A semi-automatic rifle is configured to fire single rounds of ammunition via a magazine or a belt of ammunition. A receiver cover pivots open to receive the first round of a belt of ammunition or a magazine can be inserted in a magazine well. The rifle operates using a closed bolt firing cycle, with a sliding hammer that, on its return from recoil after firing a first round, is caught by a sear regardless of whether the trigger is still in the pulled position. The trigger must be fully released before a second round can be fired.
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This is a continuation-in-part of U.S. Ser. No. 7/324,461 entitled "Method and Device for the Biological Control of Cockroaches" filed Mar. 15, 1989, by Haim B. Gunner, Fernando Agudelo-Silva, and Carol A. Johnson issued Oct. 15, 1991 as U.S. Pat. No. 5,057,315.
BACKGROUND OF THE INVENTION
The present invention is in the field of biological control of insect pests, specifically in the area of use of entomopathogenic fungi for the control of flying insects.
Control of the house fly is of major economic importance throughout the world because of public health concerns. The fly has the potential to mechanically transmit a wide variety of human pathogens, as reviewed by Bida Wid, S. P., J. I. Braim and R. M. Matossian, Ann. Trop. Med. Parasitol. 72(2): 117-121 (1978). The fly can also be annoying to people, livestock and poultry, to the extent that it even decreases time spent by animals in feeding, thereby decreasing feed efficiency.
Because of the economic and public health importance of the house fly, a significant amount of effort has been devoted to develop methods to control it. The biggest effort has been directed towards chemical insecticides, as reviewed by J. G. Scott and D. A. Rutz, J. Econ. Entomol. 81(3): 804-807 (1988). The use of chemical insecticides has a number of serious drawbacks, such as the destruction of non-target biological control agents, development of insecticide resistance, harmful levels of insecticide residue and environmental pollution. Therefore, it is desirable to have less ecologically-disruptive means to control house flies.
New approaches to fly control include the use of parasitoid wasps of various genera, as reported by J.D. Mandeville, et al. Can Ent 120: 153-159 (1988). This method of control reduces the fly population but is not adequate in itself to provide satisfactory fly control.
Insect pathogens are a possible alternative to the common use of highly toxic chemical insecticides for the control of insect pests. Fungi are one of the promising groups of insect pathogens suitable for use as biological agents for the control of insects.
Fungi are found either as single cell organisms or as multicellular colonies. While fungi are eukaryotic and therefore more highly differentiated than bacteria, they are less differentiated than higher plants. Fungi are incapable of utilizing light as an energy source and therefore restricted to a saprophytic or parasitic existence.
The most common mode of growth and reproduction for fungi is vegetative or asexual reproduction which involves sporulation followed by germination of the spores. Asexual spores, or conidia, form at the tips and along the sides of hyphae, the branching filamentous structures of multicellular colonies. In the proper environment, the conidia germinate, become enlarged and produce germ tubes. The germ tubes develop, in time, into hyphae which in turn form colonies.
One would expect that pathogens had been extensively considered as biological control agents, however, a review of the literature reveals the scarcity of pathogens that appear to offer potential to control M. domestica. The bulk of scientific literature on associations of pathogens with house flies refers to isolated reports of diagnosis of dead flies or laboratory studies without practical, short-term applications.
An extensive review of the literature reveals only isolated cases of fungal infection (see, for example, Table 1 in Briggs and Milligan, Bull. World Health Organization 58(Supplement): 245-257 (1980); Briggs and Milligan, Bull. World Health Organization 55(Supplement): 129-131 (1977)). Most reports of fungi associated with flies appear to refer to situations where the fungi did not cause patent infections or major predictable collapses of fly populations. Therefore, it does not appear as though fungi can be practically used for fly control. For example, although the fungi Aspergillus niger, A. flavus, A. ustus and Mucor racemosus from pupae or adults of M. domestica by Zuberi, et al., Pakistan J. Sci. Ind. Res. 12, 77-82 (1969) there was no evidence that these fungi were inflicting serious pathological effect on the fly populations.
It is possible to infect adult house flies with fungi under certain laboratory conditions, leading to death of the infected flies. For example, Aspergillus flavus was pathogenic to M. domestica when the insects were fed high concentrations (up to 1×10 9 ) of fungal spores, presumably due to toxins in the spores. Mortality after seven days of exposure was 57%; mortality was 100% twenty-one days after exposure. One hundred percent mortality occurred in flies seven days after they were anesthetized and placed in contact with fungal spores, as reported by Amonker and Nair, J. Invertebr. Pathol. 7: 513-514 (1965). Dresner, J. N.Y. Entomol. Soc. 58: 269-279 (1950), also reported that an isolate of the fungus Beauveria bassiana infected adult M. domestica when the insects were exposed to a dust of germinating conidia adhered in a nutrient medium. The fungus was also infective to flies when the insects were exposed to a dish of milk containing fungal conidia.
D. C. Rizzo conducted studies, reported in J. Invert. Pathol. 30, 127-130 (1977), on the mortality of flies infected with either Metarhizium anisopliae or Beauveria bassiana and determined that the time to death after infection was independent of age. Flies were infected by rolling them for ten minutes in four-week-old fungal culture slants until they were completely exposed to the spores, then maintaining them in humidity chambers. As noted by the author, in reference to the infecting fungi, "these pathogens have never been reported as having caused mycoses in fly populations in nature" at page 127.
In 1990, however, D. C. Steinkraus, et al., reported in J. Med. Entomology 27(3), 309-312, that Musca domestica L., infected with Beauveria bassiana had been found on dairy farms in New York, although at a prevalence of less than 1% (28 out of 31,165). Isolates of the fungi were infective for laboratory raised flies, but the low naturally occurring incidence led to the conclusion by the authors that "it seems unlikely that these infections represent naturally occurring epizootics within house fly populations" at page 310.
These studies have led to the recognition that there is a potential for fungal control of insects. However, no one has yet developed a consistent and commercially viable way of infecting insects and assuring that the fungi are dispersed throughout the breeding populations. For example, with reference to house flies, it is clearly impractical, and will make the registration of any product with the Environmental Protection Agency in the United States very difficult, to disperse conidia on surfaces or dishes of nutrient media whenever there is a need to control the fly population.
As of this time, there has been no successful demonstration by others of the practical, reliable and economical employment of an entomopathogenic fungus for the management and biological control of flying insects such as the common housefly.
It is therefore an object of the present invention to biologically control flying insects, especially the housefly, using entomopathogenic fungi.
It is a further object of the present invention to provide a device for the convenient, reliable and economically feasible application of fungi in the biological control of flying insects.
SUMMARY OF THE INVENTION
A method for control and extermination of flying insects, especially the housefly, by infection of the insects with an entomopathogenic fungus by means of an infection chamber. The chamber maintains the spores of a fungus pathogenic to the insects in a viable form, protecting the fungi from the environment (including rain, ultraviolet light and the wind), serves as an attractant for the insects, and serves to inoculate the insects with high numbers of spores. The fungal culture provides a continuous supply of spores over a prolonged period of time, even if desiccated. The spores attach to the insects and originate germ tubes that penetrate into the insect, which can result in death within three to four days. The chamber design, i.e., shape and color, can be the sole attractants for the insects. Alternatively, food or scents can be used to further enhance the attraction of the insects for the chamber. Although the primary means of infection is by external contact, the insects may also be infected by contact with each other and by ingestion of the spores.
The two most preferred entomopathogenic fungi are Metarhizium anisopliae and Beauveria bassiana, although other fungi can be used which are pathogenic when the insect is inoculated via the infection chamber, such as Paecilomyces and Verticillium. Examples demonstrate control of Fannia canicularis and Musca domestica under laboratory conditions and of Musca domestica in chicken coops using chambers containing Metarhizium anisopliae. Although exemplified as a method for fly control, the chamber can also be used for control of other flying insects that will enter the chamber and be infected by the fungus.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an infection chamber for infection of flies by entomopathogenic fungi, consisting of a housing, culture medium, sporulating fungal culture, and attractant. FIG. 1A is viewed from the exterior of the chamber; FIG. 1B is a view of the interior bottom portion of the chamber.
FIG. 2 is a graph of the mortality of M. domestica (% survival) as a function of time after exposure (days) to a chamber containing Metarhizium anisopliae (-[]-); formaldehyde treated fungus (diamond); or chamber without fungus (-[-]-).
FIG. 3 is a graph of the mortality of M. domestica (% survival) as a function of time after exposure (days) to a chamber containing Beauveria bassiana (diamond) or chamber without fungus (-[-]-).
FIG. 4 is a graph of the mortality of Fannia canicularis (% survival) as a function of time after exposure (days) to a chamber containing Metarhizium anisopliae, strain ATCC MA 38249 (diamond) or ATCC MA 62176 (-[]-), or chamber without fungus (-[-]-).
FIG. 5 is a graph of the mortality of Fannia canicularis (% survival) as a function of time after exposure (days) to a chamber containing Beauveria bassiana, strain ATCC 24318 (diamond) or ATCC 48585 (-[]-), or a chamber without fungus
FIG. 6 is a graph of the cumulative percent mortality of Musca domestica (10,000 flies/coop) as a function of time after exposure (days) to Metarhizium anisopliae in chicken coops: flies collected on day 4 (-[]-), flies collected on day 8 (-[]-), flies collected on day 11 (triangle), and flies collected on day 15 (reversed arrows).
FIG. 7A is the percent reduction in resting flies of M. domestica (10,000 flies/coop) as a function after exposure (days) to M. anisopliae in chicken coops.
FIG. 7B is the percent reduction in fecal/vomit spots of M. domestica (10,000 flies/coop) as a function of time after exposure (days) to M. anisopliae in chicken coops.
DETAILED DESCRIPTION OF THE INVENTION
Under normal circumstances, flying insects are not exposed to high concentrations of spores of soil-dwelling entomopathogenic fungi. The primary advantages of the infection chamber are that (1) it concentrates an extremely high number of fungal inoculum in a very small space within the infection chamber, forcing entering insects into contact with the spores which infect and kill the insects, and (2) it contains the fungal spores, resulting in minimal exposure of the environment to the pathogenic fungi, and protecting the fungus from the environment, thereby increasing viability of the culture and minimizing contamination of the fungal culture.
The devices described below provide a convenient, non-toxic and reliable method for the administration of entomopathogenic fungi in an economical and cost-effective fashion. The small, lightweight infection chambers are unobtrusive and are easily placed in locations of heavy insect infestation, increasing the efficacy of the device. Because the devices provide an environment within which the fungus can flourish over extended periods of time, a single device is effective for a longer period of time than with other methods, such as spraying, where effectiveness of the agent dissipates over a short time. The longevity of the devices also decreases the number of applications and maintenance time required for effective treatment. Another advantage of the devices is that they are constructed of readily available and relatively inexpensive materials, which insures an abundant supply of cost-effective devices.
Although described with reference to flies, especially the common housefly M. domestica, the term "flies" is used to refer to any type of flying insect which will enter the device and be infected by the entomopathogenic fungi. Examples of flying insects include other flies such as the little housefly (Fannia canicularis), tsetse fly, Mediterranean fruit fly, and Oriental fruit fly, wasps, white flies, and the adult forms of some insects, such as the corn rootworm, Diabrotica undecempunctata.
In a preferred embodiment, the flies are infected by exposure to the fungus in small chambers having apertures through which the flies enter and exit. A fly enters the chamber either as the result of general exploration or, more generally, as the result of being lured inside the device by the action of fly attractants (such as food sources, pheremones, or the color and shape of the chamber). Once inside the chamber the fly comes in contact with the entomopathogenic fungus. The conidia of the pathogen attach to the body of the fly. The infected fly leaves the chamber. Conidia attached to the fly's integument can be dislodged and may contaminate the habitat, thereby exposing additional flies to infectious spores. Further, after the fly dies and the fungal mycelium sporulates on the body of the insect, other flies can be infected by exposure to the conidia produced on the dead insect.
As diagrammed in FIG. 1, an infection chamber 10 can be constructed using standard technology to form a container 12 for fungal culture medium 14 and a cover 16 for the chamber, having openings 18 allowing insects free access to the interior of the chamber. The fungus grows on the medium 14, forming mycelia 20 and spores 22. A food attractant 24 is located on the interior of the chamber 10, in close proximity to the spores 22. The attractant is optionally located on a platform secured to the container 12 or the cover 16 to avoid direct contact with the fungus, which can serve as a landing platform for the flies. The moisture content can be regulated by the design of the chamber, for example, by the size and number of openings. In the preferred embodiment, the chamber is hung via a hook 28 in a location most likely to attract flying insects.
The chamber can be constructed using conventional materials, including glass or metal, but is preferably constructed of an extrudable or moldable plastic to keep costs to a minimum. The chamber must have openings large enough to allow free passage of the insects. The top of the chamber preferably fits securely over the bottom, or the chamber is constructed of one piece. The location of food attractants and landing platform, if any, should be such that the insects are forced into close contact with the spores. The chamber can be designed so that the fungus grows on the bottom, top and/or sides of the chamber, to maximize infectivity. The insects are infected when they contact the fungus in the chamber, or when during grooming from spores acquired on their feet.
Suitable culture media are known which can be used in the chamber. Examples of media known to those skilled in the art and which are commercially available include potato, dextrose, agar, or rice agar.
An example of a useful culture medium for Metarhizium and Beauveria consists of 1% dextrose, 1% yeast extract, 5% rice flour, 1.5% agar and 0.5% 5× Dubois sporulation salts. The 5× Dubois sporulation salts consists of 15 g (NH 4 ) 2 SO 4 /1000 ml; 0.30 g MgSO 4 7H 2 O/1000 ml; 0.15 g MnSO. H 2 O/1000 ml; 0.0375 g CuSO 4 5H 2 O/1000 ml; 0.0375 g ZnSO 4 7H 2 /1000 ml; and 0.0038 g FeSO 4 7H 2 O/1000 ml. Each salt is completely dissolved before the next salt is added and the solution is autoclaved.
The culture medium is inoculated with spores of the appropriate fungal pathogen (inoculation is accomplished by streaking the surface of the medium with an inoculating loop carrying fungal spores or by mixing the spores with the liquid medium). After seven days of growth at 28° C. with 75% relative humidity, the fungus will have produced a thick layer of mycelia and conidia that cover the surface of the culture medium.
Attractants that are useful will be dependent on the type of flying insect to be controlled. For example, attractants for flies include fruit, such as raisins, pheromones such as the sex pheromone muscalure, described by Carlson and Bereza Environ. Entomol. 2, 555-560 (1973), and synthetic compounds, such as the feeding attractant Lursect™, McClaughlin, Gormley and King Co., Minneapolis, Mn. The shape and/or color of the chamber, as well as the location of the chamber, can also be used to attract flying insects. Three studies conducted on the spatial and temporal responses of flies to attractive bait, and the attractiveness and formulation of different baits, are reported by Willson and Mulla, in Environ. Entomol. 4(3), 395-399 (1975) and 2(5), 815-822 (1973) for Musca domestica and by Mulla, et al., Environ. Entomol. 66(5), 1089-1094 (1973).
At least two species of entomopathogenic fungi have been shown to be effective in control of the housefly, Metarhizium anisopliae and Beauveria bassiana. Others that should be useful are fungi that are easy to grow on artificial media and quickly grow and produce large amounts of conidia. Examples include Verticillium and Paecilomyces spp.
The following non-limiting examples demonstrate the efficacy of the infection chambers in controlling flies. In all cases the fly populations were significantly reduced by the fungus present in the infection chambers.
EXAMPLE 1
Infection of Musca domestica with Fungi in Infection Chambers
House fly pupae were placed in closed cages that had either a fly chamber with sporulating fungus (treatment chamber) or a control chamber without fungus. Vials containing sugary water, cotton, and powdered milk were provided in each cage to assure that the adult flies had an energy source and water when they emerged from the pupae.
After the adult flies emerged, mortality was recorded daily and plotted. Selected dead flies from the treatment chamber were surface-sterilized, examined under the microscope and found to be infected, and incubated in wet chambers to ascertain whether the entomopathogenic fungus that was in the treatment cultures would grow from the dead flies.
Exposure of the adult flies to the chambers containing either the fungi Metarhizium anisopliae or Beauveria bassiana resulted in a significant reduction in survival of adult house flies as compared to flies exposed to chambers without fungus, as shown by FIGS. 2 and 3, respectively. FIG. 2 summarizes the results of the study where flies were exposed to M. anisopliae. 80% of the flies were dead after only five days; almost 100% were dead by seven days following exposure to the fungus. Formaldehyde-killed fungus did not result in a greater mortality than controls exposed to the chambers without fungus. FIG. 3 summarizes the results of the study where flies were exposed to B. bassiana. Essentially 100% of the flies were dead by four days following exposure to the fungus.
Dead surface-sterilized flies from the treatment chambers where flies were exposed to B. bassiana were found to contain fungus inside of the opened bodies. Control flies not exposed to the fungus did not contain fungus. This demonstrates that the fungus infected the flies and invaded the flies internally before they died.
EXAMPLE 2
Infection of Fannia canicularis with Fungi in Infection Chambers
Fly pupae were placed in closed cages. One week after emergence either a fly chamber with sporulating fungus (treatment chamber) or a control chamber without fungus were added to the cage. Vials containing sugar, powdered milk, water and cotton were provided in each cage to assure that the adult flies had an energy source and water when they emerged from the pupae. Fungi were obtained from the American Type Culture Collection, 12301 Parklawn Drive, Rockville, Md. 20852, USA, where they are available without restriction.
After the adult flies emerged, mortality was recorded daily and plotted. Exposure of the adult flies to the chambers containing either of two strains of the fungi Metarhizium anisopliae or Beauveria bassiana resulted in a significant reduction in survival of adult house flies as compared to flies exposed to chambers without fungus, as shown by FIGS. 4 and 5, respectively. FIG. 4 summarizes the results of the study where flies were exposed to M. anisopliae strains 62176 and 38249. 80% of the flies were dead after only six days; almost 100% were dead by eight days following exposure to the fungus. FIG. 5 summarizes the results of the study where flies were exposed to B. bassiana strains 24318 and 48585. Essentially 100% of the flies were dead by four days following exposure to the fungus.
EXAMPLE 3
Control of Musca domestica in chicken coops using chambers containing Metarhizium anisopliae
The effectiveness of the chambers containing fungus for control of flies under field conditions, in contrast to laboratory conditions, was determined using two chicken coops 12'×12'×6', containing 20 chambers per coop, fresh chicken and cow manure, and 10,000 M. domestica flies. 100 flies were removed per coop four, eight, eleven and fifteen days after exposure to the chambers and reared in the laboratory to determine mortality. Fifteen paper sheets (8.5"×11") were placed in each coop for counting resting flies. Fifteen 3"×5" cards were placed in each coop for counting fecal and vomit spots as an indicator of the number of flies remaining after exposure to the chambers.
The results, graphically shown in FIG. 6, demonstrate that 100% mortality was achieved of all flies collected from the coops having chambers containing fungus. The results shown in FIG. 7A of the numbers of resting flies indicate a 78% reduction in flies by the fifteenth day. The results shown in FIG. 7B of the numbers of vomit spots and feces indicate an 80% reduction in flies by the fifteenth day of the study.
Modifications and variations of the method and device for biological control of flying insects using entomopathogenic fungi will be obvious to those skilled in the art from the foregoing detailed description. Such modifications and variations are intended to come within the scope of the appended claims.
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A method for control and extermination of flying insects, especially the housefly, by infection of the insects with an entomopathogenic fungus, preferably soil-dwelling fungi, by means of an infection chamber. The chamber maintains the spores of a fungus pathogenic to the insects in a viable form, serves as an attractant for the insects, and serves to inoculate the insects with high numbers of spores. The spores attach to the insects and originate germ tubes that penetrate into the insect, resulting in death within three to four days. The chamber design, i.e., shape and color, can be the sole attractants for the insects. Alternatively, food or scents can be used to further enhance the attraction of the insects for the chamber. Although the primary means of infection is by external contact with the fungal growth, the insects may also be infected by contact with each other and by ingestion of the spores.
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This nonprovisional application claims priority under 35 U.S.C. § 119(a) on German Patent Application No. DE 102004050003.7, which was filed in Germany on Oct. 14, 2004, and which is herein incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus for comminuting material having a cool air channel.
2. Description of the Background Art
During the comminuting of materials in conventional devices, a considerable part of the energy required for the comminuting is converted into heat. This is caused by friction and impact forces the materials are subjected to during the comminuting process, and which primarily affect the comminuting tools.
A characteristic of conventional devices during operation is air flow, which, apart from the centrifugal force, is the force that moves the materials. This so-called self-ventilation can be generated by the device itself and/or initiated from the outside. If the material is not heat-sensitive, the innate self-generated flow of air in conventional devices is sufficient to cool down the comminuting tools such that any adverse effects on the material are eliminated.
Problems occur on a regular basis, when heat-sensitive materials are to be comminuted. Especially when plastics with a low melting point are to be comminuted, operators of conventional devices face a difficult task. On the one hand, the milling of the material is to be done at barely below the melting point in order to attain as high a machine output as possible. If the material-dependent temperature limit is thereby exceeded, the material softens and begins to melt with the result that individual particles bake together such that the size of the particles and the particle distribution of the milled material are no longer within the desired range. On the other hand, the overheated particles bake onto the machine parts, particularly the milling tools, so that the machine efficiency as well as the quality of the finished product leave much to be desired.
This problem is compounded when fine-milling heat-sensitive materials because it was found that the finer the finished product is to be, the more comminuting work has to be done, and the greater the heat generation in the area of the comminuting tools will be.
To avoid thermal overstress of the material during the comminuting process, it is common to lower the machine output of comminuting devices. In this way, less comminuting work is done per unit of time, thus generating less excess heat. However, as a consequence, the comminuting apparatus does not operate at full capacity, which goes against the fundamental requirements for an economical operation of such devices. One conventional solution is to increase the air volume beyond the self-ventilation of a conventional comminuting device by adding blowers in order to be able to vent additional heat.
Moreover, a device is known from DE 360 295 A1 having two axially spaced milling disks for forming a milling gap. The disk on the material-intake side is rigidly attached to the housing and is provided with openings for feeding the material into the device. The rear disk is positioned on a drive shaft to execute a rotational movement. For additional cooling, the rear disk is thick-walled and provided with a hollow space. The drive shaft, which is formed as a hollow shaft, has two channels, one of which feeds cooling fluids into the hollow space, whereas the other serves as the return line for the cooling fluids from the hollow space.
From U.S. Pat. No. 3,302,893, a device is known, wherein two axially opposed and rotating milling disks form a radial milling gap. The disk at the material-intake side has two openings to feed the material to the milling gap. The drive shaft for the rear milling disk is a hollow shaft for forming a cooling channel, from which cooling lines that are arranged in a star-shaped pattern in the area of the rear disk, lead to the comminuting tools. Cooling fluids from the cooling lines are directed to the area of the comminuting tools.
An additional device of this class is disclosed in U.S. Pat. No. 3,584,799. A milling disc rotates opposite a stationary milling ring, which is arranged at the intake side of the housing. The stationary milling ring is cooled with cool water, which is introduced via an annular groove in the housing, and distributed.
The disadvantage of this device is the need to provide a further cooling medium in addition to air. The additional technical expenditure necessary for storing, cooling, and conveying the cooling medium makes this device costly, in regard to both acquisition and operation.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to increase the machine efficiency of conventional devices without thereby exposing the material to additional thermal stress.
A first benefit of the invention is that in addition to cooling the milling gap with self-generated air, additional cool air is introduced into the device in accordance with the present invention. The thus increased air volume makes it possible to discharge additional heat so that the comminuting tools and the materials to be milled are exposed to considerably less heat. This allows the improvement of the operational performance, and thus also the cost effectiveness of devices of the present invention.
An additional benefit is derived from using air as a cooling medium. Air is available free of charge and in unlimited quantities everywhere, and can be introduced in a simple way via the openings in the intake side of the front housing wall, for example. After the heat transfer from the comminuting tools into the cool air, it can be released into the ambient air without much effort, after first filtering out the milled material, if necessary. This does not require much in technical equipment so that cool air can be utilized very economically as a cooling medium. Furthermore, air is neutral to the material, that is, it does not alter its chemical or physical characteristics.
In a beneficial embodiment of the invention, the openings on the intake side for feeding the cool air conduit with cool air are connected to one another via an annular channel. This simplifies the construction, particularly in connection with the use of cool or compressed air, which otherwise would have to be channeled individually to each opening.
To improve the heat transfer from the disks into the cool air, it is suggested in a preferred embodiment of the invention to provide radial ribs in the cool air conduit, which are mounted to the disk that is located at the intake side. The cooling effect thus achieved occurs in stationary, as well as in rotating milling disks. An additional feature of the rotating milling disks is that the radial ribs cause an outward radial movement of the cool air stream. Thus, the radial ribs support the cool air flow.
It is thereby beneficial for the radial ribs to extend nearly across the entire width of the cool air conduit in order to make available as large an area as possible to the cool air for heat exchange. In combination with rotating disks, larger radial ribs have the additional benefit of higher tractive power of the cool air flow.
By arranging the radial ribs near the comminuting tools, the location of the heat generation and the location of the heat removal are in close proximity to one another, which results in an optimized heat removal. In this way, excess heat is very quickly and efficiently removed.
In a further embodiment of the invention, air-conducting elements are arranged in the cool air conduit, which ensure a flow path that is effective for the cooling down of the comminuting tools. It is thereby achieved that the cool air brushes over the areas of the disk that are affected the most by the excess heat. Since the cooling potential of the cool air is thus fully utilized, the best possible cooling effect is thereby achieved.
The geometric shape of the air-conducting elements can be such that the air stream follows the geometry of the surface of the disk. When the surface of the disk is not even, the flow path and thus the contact time between cool air and disk is extended, resulting in a high heat transfer. This measure is of particular importance with devices of the present invention that have a milling gap that is tilted towards a radial plane, and/or an existing intake cone.
Preferably, the air-conducting elements are provided in the area of the radial ribs in order to obtain an interaction of radial ribs and air-conducting elements, particularly with rotating disk. In this way, the supportive effect of the radial ribs on the cool air flow is increased.
An air-conducting element that is suitable for this purpose has a trapezoidal cross section and is annularly arranged around the axis of rotation. This takes into account aerodynamic considerations on the one hand, and on the other hand, allows the ring surface, which is located opposite the trapezoidal base, to interact with the radial ribs.
According to a particularly beneficial embodiment of the present invention, a further cool air conduit is provided in a corresponding fashion between the rear wall of the housing and the rear disk. Thereby, the comminuting tools that are arranged on the rear disk are also cooled. In this way, a symmetrical and thus even cooling of all comminuting tools is achieved. The comminuting tools are thereby cooled down on their active side by the self-generated air flowing through the milling gap, and on the opposite outer side by the cool air flowing through the cool air channel. Thus, the greatest-possible heat removal of a device of the present invention is achieved.
In a preferred embodiment of the present invention, the comminuting room is divided into two chambers. One chamber is thereby entirely dedicated to the material and the second chamber exclusively to the cool air. This allows an independent supply of the device with material or with cool air, which further optimizes the comminuting process.
Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description. For example, the illustrated embodiment relates to a disk mill having an inclined milling gap, however, the invention is also applicable to disk mills with a radial milling gap, pin mills, refiners, etc.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus, are not limitive of the present invention, and wherein:
FIG. 1 is a front view of a device of the present invention, with the housing door open;
FIG. 2 is a front view of the device illustrated in FIG. 1 , with the housing door closed;
FIG. 3 is a vertical cross section along the line III-III of the device illustrated in FIG. 2 ;
FIG. 4 is a partial cross section of the upper part of the device illustrated in FIG. 3 ; and
FIGS. 5 and 6 each illustrate a partial cross section of the upper part according to a further embodiment of the present invention.
DETAILED DESCRIPTION
FIGS. 1 and 4 illustrate the detailed construction of an apparatus of the present invention. To begin with, FIGS. 1 and 2 , which show a front view of the device with the housing door 7 open and closed, respectively, illustrate a machine substructure 1 , the feet 2 of which rest on the ground/floor. The upper part of the machine substructure 1 forms a platform, on which the comminuting apparatus of the present invention is mounted.
The comminuting apparatus includes a drum-shaped housing 3 about an axis 14 , and which encloses a comminuting room 4 . On its front side 5 , the housing 3 has a central circular opening 6 , which can be closed with a housing door 7 that is pivotable around a vertical axis 8 and can be bolted shut with bolts 9 .
The housing door 7 also has a central circular feeder opening 10 , into which a chute 11 , connected by a flange 12 , terminates, the chute extending from the outside in a vertical direction, and in the bottom area in a transverse direction. From the interior of the housing door 7 is a short, conically expanding connecting piece 13 , which encloses the rim of the feeding opening 10 .
Furthermore, the housing door 7 has a plurality of equally spaced openings 15 , which are located on a circumference that is concentric to the axis 14 , and which connect the comminuting room 4 with the exterior of the mill. A ring channel 16 , which also extends concentrically to the axis 14 , covers the openings 15 on the exterior of the housing door 7 , thus connecting them with one another. The ring channel 16 is fixedly attached to the housing door 7 and has a connector 17 in the lower apex, through which air can be introduced from an air conditioning system (not illustrated). The flow of the cool air is indicated by the arrows 18 ( FIG. 3 ).
On the inner side of the housing door 7 , in the area between the openings 15 and the edge of the housing door 7 , an annular air-conducting element 38 , which is also arranged concentrically to the axis 14 , is shown. The air-conducting element 38 is formed by a sheet of metal with a trapezoidal cross section, which is attached to the inner side of the housing door 7 with its larger base. When the housing door 7 is closed, the side opposite the base of the air-conducting element 38 forms a ring surface 39 , which extends in a radial plane into the comminuting room 4 .
The finely-milled material 21 is discharged via a material discharge 20 , which in the illustration plane of FIGS. 1 and 2 extends tangentially upwards from the housing 3 , and to which a suction device can be attached, for example. Alternatively, the material discharge 20 can extend in other directions as well.
The rear wall 22 of the housing 3 is reinforced in order to form an annular ring channel 23 , which is located in a radial plane to the axis 14 , on the one hand, and, in the area of the axis 14 , to form a horizontal bearing area 27 with bearing groups 28 on the other hand. The ring channel 23 is connected to a cool air system 25 via a connector 24 . The cool air channel 23 is connected to the comminuting room 4 via a plurality of openings 26 in the rear wall 22 , which are located on a peripheral line around the axis 14 .
Through the rear wall 22 extends a shaft 29 , which can be hollow, and which is rotatably positioned in the bearing groups 28 , and with its front end reaches into the comminuting room 4 , with, for example, a multiple-groove pulley 30 attached to its exterior end. The multiple-groove pulley 30 can be connected by straps to the drive motor 31 , which is only illustrated in FIGS. 1 and 2 . The straps extend thereby inside protective sheathing 32 .
At the opposite end of the hollow shaft 29 that is located in the comminuting room 4 , a first disk 33 is mounted. The disk 33 has a central area 34 , which is level in a radial plane. In contrast, the rim area 35 adjacent thereto in a radially outward direction is angled towards the front housing side 5 in the shape of a dinner plate. On the inside of the bent rim area 35 , comminuting tools 36 are arranged in the shape of a milling ring. On the side opposite from the rim area 35 , air blades 37 , which extend radially in the area between the disk 33 and the circumference of the housing 3 , are mounted.
In addition, a plurality of radially extending ribs 55 are provided in an outer peripheral area of the central area 34 of the disk 33 , which are fixedly connected to the disk 33 . The ribs extend nearly across the entire width of the gap between the disk 33 and the rear wall 22 of the housing. For example, the ribs 55 can be 5-25 mm high and can be arranged at mutual circumferential intervals of 20-100 mm.
Inside the hollow shaft 29 , an additional drive shaft 40 is rotatably positioned in the bearing groups 41 . The rearward end of the drive shaft 40 , which runs horizontally through the rear wall 22 of the housing, also has a multi-groove pulley 42 for connecting to an additional electric motor. At the end of the drive shaft 40 extending into the comminuting room 4 , a second disk 44 is seated by its hub 43 ( FIG. 4 ). The first disk 33 and the second disk 44 are arranged coaxially to one another and rotate around a mutual axis 14 .
As can be particularly seen in FIG. 4 , adjacent to the hub 43 of the second disk 44 and extending in a radial direction is an essentially plane disk element 45 , which is separated into several sector-shaped partitions 46 that are bound by radial tie bars 56 . On the front side of the disk element 45 in close proximity to the axis, the partitions 46 form trenches, which radially outwards form channels 47 , which allow the passing of material from the front to the rear side of the second disk 44 .
To assure that the entire material reaches the channels 47 , a concentric, truncated hollow cone 48 is arranged on the front side of the disk element 45 , the base of which connects to the trenches in the area of the sector-shaped partitions 46 . With its narrow opening, the truncated hollow cone 48 forms a gliding connection to the hollow cylinder-shaped connecting piece 13 . The rim area of the second disk 44 supports the comminuting tools 49 , which are positioned at a parallel distance opposite the comminuting tools 36 of the first disk 33 . In this way, a milling gap 53 is formed that is tilted toward a radial plane.
Between the truncated hollow cone 48 and the comminuting tools 49 , on the side that is assigned to the housing door 7 , the second disk 44 has a plane ring surface 50 , which extends at the same radial distance to the axis 14 as the ring surface 39 of the air-conducting element 38 . Starting at the openings 15 in the housing cover 7 between air-conducting element 38 and the truncated hollow cone 48 , the ring surface 50 as well as the comminuting tools 49 of the second disk 44 , a cool air conduit 51 , through which cool air can flow radially, is thus formed.
On the ring surface 50 of the second disk 44 , a plurality of ribs 52 , which are radially oriented and extend nearly across the entire width of the cool air conduit 51 , that is, almost all the way to the ring surface 39 , are evenly distributed around the circumference. For example, the ribs 52 can be 5-25 mm high and can be arranged at mutual peripheral intervals of 20-100 mm.
In practical application, a device of the present invention works as follows: With the disks 33 and 44 counter-rotating, or rotating unidirectional with rotational speed difference, the material indicated by arrows 54 is introduced into the chute 11 . In this way, it is conveyed, via the feeder opening 10 , to the comminuting room 4 , where it first encounters, in an axial direction, the second disk 44 . There it is received by the recessed partitions 46 . As a result of the rotating of the disk 44 , it is rerouted by centrifugal forces into a radial direction and then flows through the channels 47 , which subsequently transport it to the milling gap 53 . In the milling gap 53 , the material 54 is comminuted by impact and friction forces generated by the comminuting tools 36 and 49 . Part of the energy supplied to the device is thereby converted into heat. After exiting the milling gap 53 , the milled material, together with the air generated by the radial air blades 37 while rotating around the axis 14 , arrives at the peripheral area of the housing 3 , which it exits tangentially through the material discharge 20 .
The heat generated during the comminuting process causes the comminuting tools 36 and 49 to heat up, whereby a part of this heat is transferred to the first disk 33 and/or the second disk 44 due to heat conduction. A first cooling of the comminuting tools 36 and 49 occurs through self-generated air, which, together with the material 54 , flows through the device, including the area of the milling gap 53 .
An additional cooling of the first disk 33 is accomplished by introducing cool air from the air conditioning system 25 via the connector 24 into the ring channel 23 . From there, the cool air flows through the openings 26 into the ring-wheel shaped gap between the real wall 22 of the housing and the first disk 33 , from where it flows along the ribs 55 radially outward, whereby a heat transfer from the ribs 55 into the cool air takes place. The ribs 55 rotating with the disk 33 thereby generate an additional propulsion impulse onto the cool air.
On the front side 5 of the device, cool air 18 flows into the annular channel 16 via the connector 17 . In the annular channel 16 , a distribution of the cool air 18 , and thus an even supply of the openings 15 with cool air 18 , takes place so that cool air 18 is evenly distributed through the openings 15 into the cool air conduit 51 , through which it flows radially. The cool air 18 brushing by the radial ribs 52 thereby absorbs heat, at the same time receiving a motion impulse from the radial ribs 52 that are brushing past the ring surface 39 at close proximity. The heat-loaded cool air 18 exits the housing 3 via the material discharge 20 , together with the self-generated air and the milled material.
FIG. 5 shows the application of the invention to a mill construction, whereby one milling ring is stationary and the other milling ring is rotating. Otherwise, the mill is rather identical with the mill described in FIGS. 1 to 4 so that the description thereof applies here also.
Illustrated in detail is a drum-shaped housing 61 encircling an axis 60 and enclosing a comminuting room 62 . On its front side, the housing 61 is accessible via a housing cover 63 , which can be swung open for this purpose. In its center, the housing cover 63 has a feeder opening 64 , adjacent to which is a chute 65 (only partially shown) for feeding material into the mill.
In addition, there are a plurality of openings 66 , which are arranged at equal intervals on a periphery that is concentric to the feeder opening 64 . In the area of the axis 60 , the rear wall 67 of the housing has an aperture 68 for a horizontal drive shaft 69 . The mounting and powering of the drive shaft 69 are essentially the same as described in FIGS. 1 and 4 .
Mounted to the end of the drive shaft 69 , which is located in the comminuting room 62 , is a disk 70 arranged in a radial plane. The outer rim of the disk facing the rear wall 67 of the housing is provided with a first milling ring 71 . In order to form a milling gap 72 , a second milling ring 73 is arranged opposite the first milling ring 71 in an axial distance on the inner side of the rear wall 67 of the housing.
The opposite rim section of the disk 70 facing the housing cover 63 has a plurality of radial ribs 74 that are evenly distributed around the periphery. The radial ribs 74 thereby extend almost across the entire width of the annular chamber, which is located between the disk 70 and the housing cover 63 , forming a cool air conduit 79 .
In the area between the outer rim segment and the drive shaft 69 , there are material passages 75 , which connect the front and rear sides of the disk 70 . In order to direct the material flow to the material passages 75 , a truncated hollow cone 76 is attached to the disk 70 on the intake side and concentric to the axis 60 , which forms a gliding connector to the feeder opening 66 of the housing cover 63 .
As is illustrated in FIG. 5 , with the disk 70 rotating, the material indicated by arrows 77 is channeled through the feeder opening 66 into the comminuting room 62 during operation. From there, guided by the truncated hollow cone 76 , it travels through the material passages 75 to the area between the disk 70 and the rear wall 67 of the housing, where it is fed by centrifugal forces into the milling gap 72 , and thereby milled. The milled material is removed from the comminuting room via a material discharge (not shown).
To cool down the milling ring 71 , a stream of cool air indicated by arrow 78 is channeled through the mill of the present invention. Cool air 78 is thereby drawn through the openings 66 in the housing cover 63 and channeled into the cool air conduit 79 formed by the disk 70 and the housing cover 63 . Due to the prevailing centrifugal forces and pressure conditions, the cool air stream 78 is rerouted radially outwards, thereby brushing along the radial ribs 74 . Thereby, a heat transfer from the radial ribs 74 to the cool air stream 78 takes place so that excess heat is removed from the mill in this way.
It is noted that the present invention is also applicable to embodiments of mills, whereby the milling gap extends between the rotating milling disk and the housing door. In these instances, the milling ring on the material-intake side is arranged in an axial distance to the housing door for forming a cool air conduit so that, in turn, radially extending cooling ribs can be mounted in the area of the milling ring to offset an overheating of the comminuting tools, and thus the material.
FIG. 6 is, for the most part, identical to the embodiment illustrated in FIG. 5 so that the same reference numerals indicate the same components, and reference is made to the corresponding part of the description.
Otherwise, the embodiment of the invention illustrated in FIG. 6 differs such that the comminuting room 62 is formed like a chamber. For this purpose, the peripheral side of the disk 70 is surrounded by a coaxial ring wheel 80 . With its outer periphery, the ring wheel 80 is fixedly connected to the housing 61 , whereas its inner periphery forms a gliding connection to the disk 70 . In this way, a partition arranged in a radial plane is formed in the comminuting room 62 , comprised of the disk 70 and the ring wheel 80 , the partition dividing the comminuting room 62 into a first disk-shaped chamber 81 and a second disk-shaped chamber 82 . Consequently, this partition also continues into the material discharge 20 ( FIG. 1 ). In the area of the material discharge, a first pipe line 83 is connected to the chamber 81 , and a second pipe line 84 is connected to the chamber 82 . The pipe line 83 , for example, can lead to a filter device (not shown), where a separation of the gaseous phase of the material 77 from the solid phase takes place. The pipe line 84 can lead directly into the ambient air.
The advantage of such a device in practical application is that the material 77 , a combination of gaseous and solid material, which is fed into the comminuting room 62 does not mix with the additional cool air 78 that is channeled into the comminuting room 62 . Rather, the material 77 and the cool air 78 pass through the comminuting room 62 in two spatially separate systems so that for the extraction of the milled material as the end product, it is merely necessary to channel the gaseous and solid material mixture of the material 77 passing through the chamber 81 through subsequent filter devices. The cool air 78 flowing through the chamber 82 can directly and without additional measures be discharged into the ambient air. The thus reduced volume to be filtered allows the employment of smaller filters.
It goes without saying that the chamber-like construction of the comminuting room 62 is also possible in comminuting devices of this class that have two rotating disks, whereby cool air is channeled into the comminuting room from the front as well as from the rear, similar to the embodiments illustrated in FIGS. 1 to 4 . In such an instance, the comminuting room 62 is divided into three corresponding chambers, whereby the one in the middle is designated for the self-generated air and solid material part, whereas the remaining chambers, which are adjacent to each side in an axial direction, are exclusively dedicated to cool air for the comminuting tools, with the resulting benefits as previously described.
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are to be included within the scope of the following claims.
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An apparatus for comminuting material is provided. The apparatus includes two disks, which are arranged coaxially to one another inside a housing that encloses a comminuting room. The rim areas of the disks are positioned opposite one another, thus forming a milling gap, and are provided with interacting comminuting tools. To generate a mutual relative movement of the disks, at least one of the disks carries out a rotational motion around the mutual axis. To comminute the material, it is first fed into the comminuting room and subsequently radially channeled to the milling gap. For additional cooling, the disk on the intake side is arranged at an axial distance to the intake side of the housing front wall, thus forming a ringwheel-shaped cool air conduit. This can be charged with cool air, which flows through the conduit in a radial direction. In this way, the machine capacity can be increased without causing thermal damage to the material to be processed.
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BACKGROUND OF THE INVENTION
This invention relates generally to anti-friction bearing type spindles, shafts or axles, and more particularly, to an apparatus to control the preload force on a set of angular contact bearings which are exposed to reversing thrust loads.
When angular contact bearings are used to control the radial and/or axial displacement of the shaft, they are typically used in preloaded pairs (or multiple sets) oriented in a front-to-front, a back-to-back, tandem or any suitable combination of these mounting arrangements.
The pair of bearings are generally preloaded, such that any force exerted on the shaft in either axial direction will instantly encounter substantial resistance by the respective bearing, which is to support the load in that direction, with minimal shaft deflection.
Preload is a parasitic load imposed on the bearings for the dual purpose of controlling shaft deflections from externally applied loads and maintaining proper bearing geometry and frictional forces within the bearing for efficient performance. If the shaft is being exposed to varying speeds and loads, then it is often desired to vary the preload to obtain optimized performance.
U.S. Pat. No. 2,314,622 shows a bearing mount which involves a resilient member which applies a preload to a shaft. There are many other designs which control the preload force which is exerted upon the bearings.
U.S. Pat. No. 4,551,032 shows a spindle which has bearing members attached. A yieldable member, whose flexibility is controlled by the pressure of a fluid which is forced into a cavity in the yieldable member, and thus controls the preload which is applied to the bearings.
U.S. Pat. No. 4,850,719 shows a variable stiffness angular contact bearing wherein the stiffness of the bearing is controlled by piezoelectric wafers which control the preload applied to the bearings.
While all of the above are variable preload devices, an increase in the actuating force which applies the preload may not always result in a similar increase in force being applied to the bearings. The static frictional forces between the bearing housing interface is significant in comparison to the desired variations in preload. This static frictional force is not uniform and as a result cannot be accurately compensated in most variable preload systems. It is difficult to precisely vary the preload directly applied to the bearing, for these reasons the bearings can be overloaded if frictional forces are not adequately accounted for. A precise mechanical preload varying device is costly and requires space.
The varying preload forces of the above patents are all applied directly through the roller elements. Since the roller elements typically cannot take excessive forces, the magnitude of the forces applied by the preload are generally quite small. In all of the hydraulic and pneumatic preload systems, this results in a substantial increase in mechanical compliancy in a thrust direction.
The foregoing illustrates limitations known to exist in present bearing preload control systems. Thus, it is apparent that it would be advantageous to provide an alternative directed to overcoming one or more of the limitations set forth above. Accordingly, a suitable alternative is provided including features more fully disclosed hereinafter.
SUMMARY OF THE INVENTION
In one aspect of the present invention, this is accomplished by providing an apparatus including a shaft, with a first and a second angular contact bearing axially disposed along the shaft for supporting the shaft in a first and a second axial direction, respectively. The second axial direction is substantially opposite the first axial direction.
A preload device exerts a preload force onto the angular contact bearings, which place the angular contact bearings into a maximum preload condition. An actuator device, acting in opposition to the preload device, reduces preload from the maximum preload condition to a desired preload condition.
The foregoing and other aspects will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side cross-sectional elevation view illustrating an embodiment of a rotary shaft supported by a plurality of preloaded bearings;
FIG. 2 is a side cross-sectional elevational view similar to FIG. 1, of an alternate embodiment of rotary shaft utilizing a pin member;
FIG. 3 is a similar view to FIG. 1 illustrating another alternate embodiment of a stationary shaft supported within a rotary housing by a plurality of preloaded bearings; and
FIG. 4 is a similar view to FIG. 1 illustrating yet another embodiment of a rotary shaft supported by a plurality of preloaded bearings.
DETAILED DESCRIPTION
In this specification, identical elements in different embodiments are given identical reference characters.
Referring to FIG. 1, a rotary shaft, spindle or axle 10 is mounted in an aperture 12 formed in a housing 14 by a first and second angular contact bearing 16, 18. The instant invention relates to preload of the angular contact bearings 16, 18.
The angular contact bearings 16, 18 may be angular contact ball bearings, radial ball bearings or tapered roller thrust bearings.
Even though the instant invention is especially applicable to machine toolswith rotary spindles, it may be suitably applied to any device or vehicle with a rotating axle, shaft, spindle, or housing.
The first angular contact bearing 16 has an inner race 24 which is fixed relative to the rotary shaft 10 while an outer race 26 is fixed relative to the housing 14.
An inner race 28 of the second bearing is fixed with respect to the rotary shaft 10. Therefore, only an outer race 30 of the second angular contact bearing 18 may be axially displaced to place the first and the second angular contact bearings 16, 18 in a preloaded state.
A preload means 32 is a device, such as a high stiffness spring, whose deflection is insignificant compared to the bearing deflection at the maximum preload condition. In conjunction with the standard preloaded bearings, the preload device exerts a force on the outer race 30 of the second angular contact bearing 18, thus placing the first and the second angular contact bearing 16, 18 under the maximum preload condition. The only support for the rotary shaft 10 is the first and the second angular contact bearings 16, 18.
The manufactured in preload of bearings 16, 18 is the maximum preload condition that the angular contact bearings 16, 18 are intended to experience over the intended range of operating conditions. The maximum preload condition depends upon the spring rate of the preload device 32, the manufactured in preload of bearings 16, 18 and the spacer length differentials between axial shaft and axial housing spacers 92, 34.
A force applied from the actuating means, through the outer race 30 of the first bearing 18, 36 to the preload device 32 causes the preload device todeflect thereby reducing the initial deflection (preload) in the balls and races of bearing 16 and 18. Force applied by the actuating means 36 is transmitted through outer race 30 to the preload device 32, then through an annular channel pilot ring 37 to the housing 14. In this way, a preloadforce exerted by preload device 32 is varied and is inversely related to a actuating force exerted by the actuating means 36. This configuration avoids the possibility of overloading the rolling elements 31, 31'.
By design, preload device 32 has a stiffness much greater than that of bearings 16 and 18. As such, the forces necessary to deflect preload device 32 to its maximum position (resulting in the minimum preload on bearings) are much greater than the frictional forces between the bearing and housing interface. In this way, accurate variation of preload is effected.
The axial shaft spacer or load transmitting means 34 may be included to transfer the force from the preload device 32 to the housing.
The actuator means 36 may be a hydraulic piston, a pneumatic piston, an electro-mechanical device or any well known element in which the load or axial displacement can be varied in a controllable manner. In this instance, the actuator means 36 is controlled from variable pressure fluidsupply 41 as illustrated in FIGS. 1-4.
The actuator means 36 is the device which varies the preload, it can only act to reduce the preload applied to the bearings. The actuator means 36 in FIG. 1 acts directly through the outer race 30 of the second angular contact bearing 18. By comparison, the force exerted by the prior art variable preload devices act through the rolling elements 31, 31' of the bearings 16, 18, possibly overloading the rolling elements.
Prior art devices which vary loads tend to be expensive, imprecise or bulky. The instant configuration permits variation of the preload by the actuation means 36, without the danger of overloading rolling elements 31,31' of the bearings 16, 18, and, therefore, without extreme concern to the pressures exerted by the preload varying device.
Normal axial loads on rotary shaft 10 in direction 44 will normally be transmitted to the inner race 24, the roller element 31 and the outer race26 of the first bearing 16 and the annular channel pilot ring 37 and thenceto the housing 14.
Normal axial loads on rotary shaft 10 in direction 46 will be transmitted through the inner race 28, rolling element 31', and the outer race 30 of the second bearing 18 to preload device 32. From there, the load is transmitted via spacer 34 to the annular channel pilot ring 37 and then tothe housing 14.
FIG. 1 illustrates one system for preventing relative axial displacement between the outer race 26 of the first bearing 16 and the housing 14. The annular channel pilot ring 37 and ring member 37', which are fixed relative to the housing 14, form an annular channel 39 which conforms to outer race 26 of first bearing 16.
Another device which prevents relative axial motion between the outer race 26 of the fist bearing 16 and the first housing 14 is illustrated in FIG. 2, in which a pin 48 is inserted through the housing 14 into any intermediate element described in the preceding paragraphs, such as spacer34. Loads will be transmitted directly from the intermediate member to the housing.
The spring rates of any elements located on the opposite side of the pinnedelement from the load will thereby not contribute to the spring rate which will oppose the load. In this manner, the total deflection rate of the system can be controlled by the insertion or removal of one or more pin members depending upon which element is pinned. The pin 48 also restricts excessive axial movement of the shaft 10 relative to the housing 14.
FIG. 3 illustrates a stationary shaft 54 inserted in a rotary housing 56, the rotary housing being supported by a first and a second angular contactbearings 58, 59. This configuration functions identically to that of the FIG. 1 configuration, except that an inner race 60 of the first angular contact bearing 58 is the only race of four races 60, 62, 64, 66 which canbe axially displaced to place the two bearings 58, 60 into a preloaded state. Therefore, a preload device 67 and actuator means 68 act on opposing sides of the inner race 60 of the first angular contact bearing 58.
FIG. 4 illustrates a configuration to preload a plurality of angular contact bearings 70, 72 which is similar to the FIG. 1 configuration, except that a preload device 74 is disposed on the opposite side of the second angular contact bearing 72 from the first angular contact bearing 70, while an actuator means 76 is disposed between the first and the second angular contact bearing 70, 72.
The first angular contact bearing 70 has inner race 80 and outer race 82. The second angular contact bearing 72 has an inner race 84 and on outer race 86. The inner races 80 and 84 of the first and second angular contactbearings 70 and 72, respectively, are each fixed axially relative to the shaft 10. The outer race 82 of the first angular contact bearing 70 is restricted from axial motion relative to the housing.
The preload means 74 and the actuation means 76 interact to vary the force applied to, and the position of, the outer race 86 of the second angular contact bearing 72 relative to the housing. The outer race 86 of the second angular contact bearing is (in this configuration) the only race which can move to effect preload between the two bearings 70, 72.
These configurations illustrate the benefits of placing an actuator means and a preload means disposed on opposite sides of an axially displaceable race, in order to place a pair or multiple set of angular contact bearingsin a variable preloaded condition.
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An apparatus including a shaft, with a first and a second angular contact bearing axially disposed along the shaft to provide support for the shaft in a first and a second axial direction, respectively. The second axial direction is substantially opposite the first axial direction. A preload device exerts a preload force onto the angular contact bearings, which place the angular contact bearings into a maximum preload condition. An actuator device, acting in opposition to the preload device, reduces preload from the maximum preload condition to a desired preload condition. The preload device and the actuator device act directly through an axial displaceable race of the angular contact bearing, instead of through the rolling elements of the bearing.
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TECHNICAL FIELD
[0001] The present invention relates to a vehicle wheel rim, and more particularly, to a vehicle wheel rim that allows for vastly improved balancing of a wheel rim-tire assembly.
BACKGROUND
[0002] Vehicle wheel rim-tire assemblies are radially balanced for preventing vertical bounce of the wheel during various speeds, known as Static Imbalance or Shake. Another form of imbalance is known as Couple Imbalance or Shimmy. Radial balancing of the wheel rim-tire assembly may be accomplished by many well-known methods, such as but not limited to using a spin balance machine also known as a radial balance machine or a dynamic balancing machine, or a static bubble-type wheel balancer. Radial balancing determines the weight and the angular location for placement of the weight on the wheel rim-tire assembly for radially balancing the wheel rim-tire assembly. Wheel weights are typically placed on the inner or outer wheel lips of the wheel rim-tire assembly. Wheel weights may also be placed in an arbitrarily lateral manner on the inside of the rim surface.
[0003] It is well known in the art that a variety of types of correction weights are available for placing on the vehicle wheel to correct the measured imbalance. For example, adhesive-backed weights, patch balance weights, clip-on weights, and hammer-on weights are available from a number of different manufacturers.
[0004] Referring to FIGS. 1 and 2 , it is normally good practice to place balance weights at a particular angular location on both an inner plane 22 and outer plane 26 of a wheel rim-tire assembly 10 . This may prevent creating a lateral imbalance; such a lateral imbalance may occur if balance weights are added to only an inner plane 22 or only to an outer plane 26 of the wheel rim-tire assembly 10 . A lateral imbalance in the wheel rim-tire assembly can lead to a noticeable shake or shimmy, that sometimes can be extreme and potentially hazardous, and often cannot be alleviated by simply vertically balancing a wheel rim-tire assembly using current dynamic spin balancing or static balancing methods. If the lateral balance plane 14 of a wheel rim-tire assembly 10 is not coincident with the geometric centerline 18 of the wheel rim-tire assembly 10 , and then placing balance weights on both an inner plane 22 and outer plane 26 of the wheel rim-tire assembly 10 may still lead to lateral imbalance causing or worsening the shake or shimmy of the wheel rim-tire assembly. Additionally, some currently popular wheel rim styles may lose some or much of their aesthetic appeal if the balance weights are installed in a manner to make the balance weights clearly visible. Additionally, today's automotive manufacturers and wheel manufacturers are equipping newer high-performance models with substantially wider and larger diameter wheels. This causes even greater occurrences of laterally imbalanced wheel rim-tire assemblies. Additionally, with the advent of lost lead wheel weights due to improper adhesion, wheel weight loss in the State of California alone, constitutes over 500,000 pounds annually (circa 2008). Because of this, environmental and health concerns are at an all time high with lead wheel weights being identified as the largest new route of lead releases into the environment (Center for Environmental Health, circa 2008).
[0005] Thus, there is a need for a wheel rim that overcomes these and other disadvantages.
SUMMARY
[0006] The present invention relates to a wheel rim comprising: a lateral balance plane, defined as a plane perpendicular to the axis of rotation of the wheel rim, and upon which the wheel rim is laterally balanced; an outer surface, the outer surface facing away from the axis of rotation of the wheel rim; an inner surface, facing towards the axis of rotation of the wheel rim; and a circumferential area located on the inner surface, the circumferential area coinciding with the intersection of the inner surface with the lateral balance plane of the wheel rim, the circumferential area being visibly distinguishable from the rest of the inner surface. The circumferential area may allow technicians to place balance weights on the lateral balance plane of the wheel rim, thus preventing the creation of lateral forces during rotation of the wheel rim-tire assembly which can lead to noticeable shaking or shimmying can affect the performance and safety of the vehicle and its occupants. The present invention may save time when balancing a wheel rim-tire assembly, in that one may not have to perform a separate lateral balancing step to identify the location of the lateral balance plane. The circumferential area may be generally out of sight when the wheel rim is installed on a vehicle, so that if balance weights are attached to the circumferential area, the balance weights may also be generally out of sight, providing for greater aesthetic appeal of the wheel rim. Attaching balance weights to the disclosed circumferential area may reduce the number of thrown balance, and thereby reduce the introduction of lead into the environment.
[0007] In other embodiments of the disclosed invention, the circumferential area may be distinguished from the rest of the inner surface via a first line and a second line bordering the circumferential area; via a color applied to the circumferential area; via a polished surface applied to the circumferential area; or via a texture applied to the circumferential area.
[0008] In still other embodiments of the disclosed invention, the circumferential area may be distinguished from the rest of the inner surface, by having the circumferential area raised in comparison to the rest of the inner surface, or by having the circumferential area recessed into the inner surface.
[0009] In yet other embodiments of the disclosed invention, the circumferential area may be distinguished from the rest of the inner surface by visual markings either permanent or temporary using symbols, letters, patterns or numbers located on the circumferential area; or by having markings machined onto the circumferential area; or by having markings printed onto the circumferential area; or by having markings painted onto the circumferential area.
[0010] Technicians may be able to quickly and easily install balance weights to the circumferential area due to the circumferential area being visibly distinguishable from the rest of the inner surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The present disclosure will be better understood by those skilled in the pertinent art by referencing the accompanying drawings, where like elements are numbered alike in the several figures, in which:
[0012] FIG. 1 is a perspective view of a prior art wheel rim-tire assembly;
[0013] FIG. 2 is a side view of the prior art wheel rim-tire assembly from FIG. 1 ;
[0014] FIG. 3 is a cross-sectional view of an embodiment of the disclosed wheel rim;
[0015] FIG. 4 is a perspective view of the wheel rim from FIG. 3 , looking into the inner side of the wheel rim (the side that faces the vehicle) and out the outer side of the wheel rim;
[0016] FIG. 5 is a close-up cross-sectional view of the inner surface of an embodiment of the disclosed wheel rim, showing a raised circumferential area;
[0017] FIG. 6 is a close-up cross-sectional view of the inner surface of an embodiment of the disclosed wheel rim, showing a recessed circumferential area;
[0018] FIG. 7 is a cross-sectional view of an embodiment of the wheel rim; showing a first means of distinguishing the circumferential area;
[0019] FIG. 8 is a cross-sectional view of an embodiment of the wheel rim; showing a second means of distinguishing the circumferential area;
[0020] FIG. 9 is a cross-sectional view of an embodiment of the wheel rim; showing a third means of distinguishing the circumferential area;
[0021] FIG. 10 is a cross-sectional view of an embodiment of the wheel rim; showing a fourth means of distinguishing the circumferential area;
[0022] FIG. 11 is close-up cross-sectional view of the inner surface of an embodiment of the disclosed wheel rim, showing an extended member extending from the circumferential area; and
[0023] FIG. 12 is a perspective view of an embodiment of the disclosed wheel rim from FIG. 3 , looking into the outer side of the wheel rim (the side that faces away from the vehicle) and out the inner side of the wheel rim.
DETAILED DESCRIPTION
[0024] FIG. 3 shows a cross-sectional view of a wheel rim 30 . FIG. 4 shows a perspective view of the wheel rim 30 , looking into the inner side of the wheel rim 30 (the side that faces the vehicle) and out the outer side of the wheel rim 30 (the side that faces away from the vehicle). The wheel rim may have spokes 34 as shown, or be non-spoked. The wheel rim 30 comprises an inner surface 38 and an outer surface 42 . When the wheel rim-tire assembly 10 is assembled, the tire is normally adjacent to the outer surface 42 . As is discussed in U.S. Pat. No. 6,976,385 to Okada, and incorporated herein in its entirety, the lateral balance point of a wheel rim-tire assembly is the intersection point between the bottom of the wheel rim-tire assembly and a plane perpendicular to the wheel rim-tire assembly's rotational axis, such that the wheel rim-tire assembly is laterally balanced on the intersection point. The plane shall be called the lateral balance plane 14 . FIG. 3 shows the lateral balance plane 14 with respect to the wheel rim 30 . Although an entire wheel rim-tire assembly is not shown in FIG. 3 , just the wheel rim 30 , it should be noted that installing a tire to the wheel rim 30 should not affect the location of the lateral balance plane 14 with respect to the wheel rim 30 , however installing a tire may affect the balance and may cause the wheel rim-tire assembly to now become imbalanced. The wheel rim 30 shown in FIG. 3 illustrates how the geometric center 18 of the wheel rim 30 does not coincide with the lateral balance plane 14 of the wheel rim 30 (and the wheel rim-tire assembly). Thus, if it is determined that 1 ounce of weight needs to be placed on the wheel rim-tire assembly at 90° from a reference point on the wheel rim-tire assembly, a prior art method of placing the weight is to simply put ½ ounce of weight at the angular location on the inner plane 22 of the wheel rim, and place ½ ounce of the weight at the angular location on the outer plane 26 of the wheel rim. This dividing of the weight and installing on both an inner plane 22 and an outer plane 26 is done in order to attempt to keep the wheel rim-tire assembly balanced. However, if the wheel rim-tire assembly has a lateral balance plane 14 that is not coincident with the geometric center 18 of the wheel rim-tire assembly, then the placement of weights on both an inner plane 22 and an outer plane 26 of the wheel rim-tire assembly, may create a lateral force during rotation of the wheel rim-tire assembly. In some cases, the lateral force may be great enough to cause a noticeable shake or shimmy while driving the vehicle at various speeds. Additionally, if an entire balance weight is simply placed on either an inner plane 22 or outer plane 26 , which may be done for time considerations or to simply hide the balance weight from view for aesthetic reasons, the lateral force created during rotation of the wheel rim-tire assembly may be even greater than if the weight is split into two halves and attached to both an inner plane 22 and an outer plane 26 of the wheel rim 30 . Additionally, if the entire balance weight were to be placed on the inner wheel surface 38 of the wheel, the prescribed placement of the weights could be somewhat arbitrary with respect to the lateral placement of the weights.
[0025] Thus, in order to prevent the creation of lateral forces due to the placement of balance weights on either (a) both an inner plane 22 and outer plane 26 of a wheel rim 30 ; or (b) either just an inner plane 22 or just an outer plane 26 of the wheel rim; a circumferential area 46 dedicated for balance weight placement is identified on the inner surface 38 of the wheel rim 30 . The circumferential area 46 will be located where the lateral balance plane intersects inner surface 38 of the wheel rim 30 . The width W of the circumferential area 46 may range from about ⅛ inch to about 4 inches, and preferably range from about ¼ inch to about 3 inches. Thus the lateral balance plane 14 will intersect the circumferential area 46 in the middle of the width W. The circumferential area 46 may be identified by being raised from the rest of the interior surface 38 as shown in the cross-sectional view FIG. 5 , or in other embodiments the circumferential area 46 may be indented from the rest of the interior surface 38 as shown in the cross-sectional view FIG. 6 . In still other embodiments, the circumferential area 46 may be distinguished by being polished or textured differently from the rest of the inner surface 38 . The circumferential area 46 may be polished or non-textured to enhance the adhesiveness of the circumferential area 46 for balance weights that may be applied using adhesives.
[0026] In other embodiments of the disclosed wheel rim 30 , the circumferential area 46 may be identified by markings, such as by paint, engravings, epoxy, scoring, coating or any other suitable means to identify the location of where lateral balance plane intersects the wheel rim 30 on the inner surface 38 . The identifying markings may be either one solid line of a width W located on the inner surface 38 , as shown in FIG. 7 , or in other embodiments, 2 solid lines may identify the width of the circumferential area 46 , as shown in FIG. 8 . In still other embodiments, dashed lines as shown in FIG. 9 , or dotted lines as shown in FIG. 10 may be used to identify the circumferential area 46 . All the markings disclosed in this patent application may be machined onto the inner surface 38 , or they may be painted, or printed on the inner surface 38 , or embossed, or dye stamped. It should be noted that this disclosure encompasses any suitable means of distinguishing the circumferential area 46 from the rest of the inner surface 38 , to allow a person to place one or more balance weights within the circumferential area 46 . The markings may be permanent or temporary. Symbols, letters, numbers, patterns, knurling or colors may be used to identify the circumferential area 46 .
[0027] In still other embodiments one or more extended members 50 may be located at and extended from the circumferential area 46 , to allow for attachment of clip-on balance weights at the circumferential area 46 , as shown in FIG. 11 . In FIG. 11 please note that the circumferential area is identified from the rest of the inner surface 38 of the wheel rim 30 by the different hash marks. The extended member 50 may extend from about ¼ inch from the inner surface 38 to about 1 inch from the inner surface 38 .
[0028] FIG. 12 shows a perspective view of the wheel rim 30 , looking into the outer side of the wheel rim 30 (the side that faces away from the vehicle) and out the inner side of the wheel rim 30 (the side that faces the vehicle).
[0029] The disclosed wheel rim 30 will have a circumferential area 46 identified on the inner surface 38 of the wheel rim 30 that is coincident with the intersection of the lateral balance plane 14 of the wheel rim 30 with the inner surface 38 . The location of the lateral balance plane 14 with respect to the rim 30 (and hence the location of the circumferential area 46 to be marked on the inner surface 38 ) may be measured by any lateral balancing techniques currently known, including those disclosed in U.S. Pat. No. 6,976,385. In addition, the lateral balance plane of a rim 30 may be located during the engineering and design phases, through volumetric calculations or other formulas; using computers, 3D computer modeling programs, finite element analysis, or by other mechanical means
[0030] The disclosed invention has many advantages. The identification of a circumferential area 46 that coincides with the lateral balance plane of the wheel rim, will allow technicians to place balance weights on the lateral balance plane of the wheel rim (which should be the same as the lateral balance plane of the wheel rim-tire assembly), thus preventing the creation of lateral forces during rotation of the wheel rim-tire assembly which can lead to noticeable shaking or shimmying can affect the performance and safety of the vehicle and its occupants. The disclosed wheel rim, will save time when balancing a wheel rim-tire assembly, in that one will not have to perform a separate lateral balancing step to identify the location of the lateral balance plane. Balance weights will not be visible with the disclosed wheel rim, thus providing for greater aesthetic appeal of, sometimes very expensive, wheel rims. Additionally, the circumferential area 46 may be designed to specifically accept adhesive wheel weights. This invention may greatly reduce lost wheel weights while increasing performance, safety and may dramatically reduce the introduction of lead into the environment. The identifying markings that locate the circumferential area may be made during the manufacturing process of the wheel rim, thus making it very easy for balance technicians to see where to apply the necessary balance weights.
[0031] It should be noted that the terms “first”, “second”, and “third”, and the like may be used herein to modify elements performing similar and/or analogous functions. These modifiers do not imply a spatial, sequential, or hierarchical order to the modified elements unless specifically stated.
[0032] While the disclosure has been described with reference to several embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the essential scope thereof. Therefore, it is intended that the disclosure not be limited to the particular embodiments disclosed as the best mode contemplated for carrying out this disclosure, but that the disclosure will include all embodiments falling within the scope of the appended claims.
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A lateral balance plane, defined as a plane perpendicular to the axis of rotation of the wheel rim, and upon which the wheel rim is laterally balanced; an outer surface, the outer surface facing away from the axis of rotation of the wheel rim; an inner surface, facing towards the axis of rotation of the wheel rim; and a circumferential area located on the inner surface, the circumferential area coinciding with the intersection of the inner surface with the lateral balance plane of the wheel rim, the circumferential area being visibly distinguishable from the rest of the inner surface.
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FIELD OF THE INVENTION
This invention relates generally to an improved bucket for a flight conveyer in which an endless belt carries numerous buckets for scooping a material to be conveyed. More particularly, this invention relates to an improved bucket for mounting on a flight conveyor which uniformly filters the material as it is conveyed and removes greater volumes of solid material from a liquid than prior buckets.
U.S. Pat. No. 3,891,558, of which the present applicant is inventor, teaches an apparatus for removing oil and debris from water having buckets, or flights, with fluid release slots mounted on an endless conveyor belt. It is often desirable to filter material as it is conveyed, as shown in the U.S. Patent cited above wherein the buckets have slots to allow water to drain while the solid or quasi-solid materials are retained and subsequently dumped from the bucket as waste. Filter buckets are not only useful for separating refuse from liquid, but also for separating waste or scrap material from product, an example of which would be the filtering of dust and other foriegn matter from grain as it is conveyed.
The ability of prior art flights to scoop and retain solid and quasi-solid materials from a liquid is inherently limited. The prior art buckets will rarely retain a volume of material greater than the volume of the bucket due to a "cascade" effect of the liquid mixed with the material. As the conveyor lifts the bucket from the liquid, the liquid cascades and "washes" any solid or solid or quasi-solid material over the sides of the bucket, limiting the capacity of the bucket to its volume. In addition, the materials conveyed will include a substantial amount of liquid, which must drain as the flight is conveyed to be dumped.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an improved bucket for a flight conveyor for removing solids and quasi-solids from liquid which removes a volume of solids greater than the bucket volume by eliminating the cascading effect of the liquid.
It is a further object of the invention to provide an improved flight bucket for a conveyor system which is light, strong, easy to construct, and performs uniform filtering action on the material conveyed in the bucket.
It is a further object of the invention to provide a filter bucket with an integral and easily manufactured rake-like edge for scooping into, engaging, and retaining the material to be conveyed.
The present invention meets these objectives by providing a filter bucket with a specially designed screen construction. Numerous relatively thin, strong wires are formed in an arcuate screen configuration. The wires are fixed, uniformly spaced apart, to cross bars perpendicular to the wires, to form the concave grid-like bottom of the bucket. The side plates, which may be perforated, are rigidly fixed with the respective ends of the cross bars at each side of the bucket.
A very strong and light bucket is the result. By varying the spacing between the wires and the number of and spacing between the cross bars, a bucket for any desired filtering effect is easily provided. Providing the sides with perforations equal in diameter to the spacing between the wires further enhances uniform filtering action.
Allowing the wires to extend generally upward beyond the edge of the bucket forms a rake-like leading edge on the bucket for digging into and retaining the material to be conveyed.
The above features and advantages of the invention, along with numerous others, will become apparent upon careful reading of the following detailed description, claims, and drawings, wherein like numbers denote like parts in the several views and wherein:
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the filter bucket of the invention mounted with an endless conveyor belt.
FIG. 2 is a top plan view of the filter bucket of the invention.
FIG. 3 is a side plan view of the filter bucket of the invention.
FIG. 4 is a partial perspective view of the construction of the bucket of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The improved filter bucket of the invention is indicated generally in FIG. 1 at 1 and is mounted with an endless belt 2 carrying numerous identical buckets through a continuous cycle of scooping material, filtering it as it is conveyed upwardly, and dumping it at the upper end of the flight conveyor.
The bucket includes a bottom 3, having a concave inside configuration for retaining the materials scooped, and two sides 4. The bottom 3 comprises numerous, relatively thin and strong stainless steel wires 5 fixed, preferably by welding, to a plurality of relatively thin cross bars 6 perpendicularly disposed to the wires and preferably of the same material. As shown, each wire 5 is formed into an arcuate configuration, however, the cross bars 6 may be welded to straight wires and the resulting screen formed by bending or otherwise into the configuration desired for the bucket bottom.
As best seen in FIGS. 3 and 4, the cross bars are preferably fixed to the wires at the corners of the cross bars to minimize blockage of the screen by the cross bars, and permit liquids to freely drain through the bucket.
The leading edge 7 of the bucket, which scoops into the material conveyed, is preferably rake-like to facilitate engaging with and retaining the material which might otherwise slip out of the bucket. The rake-like leading edge 7 is formed by permitting the ends of the wires 5a to extend beyond the cross bar 6a at the ends of the bucket. It should be noted that the raking action is variable for a particular bucket by varying the number and length of wire ends 5a extending beyond the cross bar 6a at the edge of the bucket. It should be noted that the raking action is variable for a particular bucket by varying the number and length of wire ends 5a extending beyond the cross bar 6a.
The two sides 4 preferably having openings 8 formed through to permit liquids to drain. They may be constructed in a manner similar to the bottom 3 or they may be perforated thin stainless steel plates, as shown, or otherwise. The sides 4 are attached preferably by welding, to the ends of the cross bars 6 to complete the bucket assembly. Holes 8 formed through the end plates permit liquids or debris to filter through the end plates permit liquids or debris to filter through and enhance the filtering action of the bucket. The holes may be of a diameter equal to the spacing between the wires 5 of the bottom to insure uniformity of the filtering action.
Various spacings between the wires 5 and the number of and spacing between the cross bars permits the construction of an endless variety of buckets, each with different filtering characteristics for removal of different size debris. For example, a bucket having relatively few wires is best suited for removing weeds or grass from water and one having many wires and consequently smaller openings through is best suited for removing dust from a grain. Further, the open construction of the bucket allows a stream of air or water, or a suction, to be directed to the contents of the bucket to increase removal of debris.
An additional advantage of the filter bucket of the invention is that its open design and strength make it the ideal vehicle for a screen insert 12, which preferably is the same shape as the bucket to complimentarily friction fit inside and be carried and supported by the bucket. Such a screen may have little strength of rigidity by itself. However, mounting it in the bucket of the invention provides support and permits flow through the screen to freely escape through the bucket. When the filter bucket carries an insert, it is preferable that the wires 4 of the bucket bottom 3 are positioned so that a flat surface abuts the screen. Point stress on the insert is prevented and the chance of breakage or tearing of the insert by the weight of material in the bucket is thus minimized. Such a configuration is shown in FIGS. 3 and 4, where the wires are disposed to present a flat side to any insert placed therein. The wires are preferably generally triangular in cross section, as shown in FIG. 4, where the wires have a truncated triangular cross section. The narrow edge of the wire 5 is fixed with the crossbar 6 and the wider section 5b defines the inside of the bucket and provides a broad support for a screen insert 12.
In use of the filter bucket of the invention, it is typically mounted with an endless conveyor belt 2 by any convenient means shown in the art, such as a bucket 15 mounted with the bucket 1 and belt 2 for example by bolts (not shown). An end of the belt is disposed for example in a body of liquid containing solid or quasi-solid materials, which are desired to be removed. The belt is driven to move the bucket alternately into and out of the liquid to scoop the materials from it and carry them to the opposite end of the belt, where the material is dumped from the bucket. As the bucket of the invention is removed from the liquid, liquids in the material scooped from the liquid freely drain through the openings in the bucket and through the material in the bucket, thereby cascading and washing-off of the material retained above the bucket is prevented. The bucket thus retains material equal to the volume of the bucket and additionally a substantial amount of material is retained above the bucket, as shown by the dotted outline 11 in FIG. 1. In actual operation, when the filter bucket of the invention is used on an inclined conveyor such as the one of FIG. 1 to remove debris from liquids, a volume of material equal to approximately three times the volume of the bucket may be retained.
The filter bucket of the invention is further useful where it is desired to separate dust or refuse from a material. In such case, a stream of air, water, etc. may be directed on the filled bucket as it is conveyed to enhance separation of the undesired material from the material desired to be retained in the bucket. A particular application is in grain elevators, where explosive dust accumulation is a serious problem. The filter bucket of the invention may be employed on a conveyor belt having an enclosure mounted over the belt, and buckets. A suction may be applied to the housing and a strong suction applied adjacent each bucket for removing dust in the grain to prevent its accumulation in the elevator.
In case it is necessary or desirable to change the degree of filtering without removing the filter buckets of the invention from the endless belt. The change is readily accomplished by fitting a suitable insert in each flight bucket. As inserts may be provided having any size openings desired the debris removal, characteristics of the flight buckets are naturally readily and endlessly variable.
It is apparent that there has been provided in accordance with the invention a filter bucket for a flight conveyor that fully satisfies the objects, aims, and advantages set forth above. While the invention is described in connection with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications, and variations as fully within the spirit and scope of the appended claims.
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An improved filter bucket for a flight conveyor having two sides and a bottom with an integral rake edge. Numerous equally spaced apart arcuately curved wires are fixed to and supported by longitudinally extended cross bars in a grid fashion to form the generally concave bucket bottom interior surface. The wires extend beyond the cross bar at the leading edge of the bucket to form a rake edge for engaging and retaining material conveyed. Perforated sides with numerous holes formed therethrough of diameter equal to the bottom grid spacing wires provide for a uniform filtering action filtering action through the bottom and sides of the bucket.
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CLAIM OF PRIORITY
This is a continuation in part of application Ser. No. 07/923,387 filed Aug. 3, 1992 now U.S. Pat. No. 5,316,170.
BACKGROUND OF THE INVENTION
The present invention relates generally to garbage receptacles.
Waste containers for household use, and particularly those used in kitchen areas which include a foot-operated lid opening mechanism, are well known. Other kitchen-type containers that include a two-position lid are also known. Such waste containers have been immensely helpful in households.
However, it is still necessary to exert significant force to remove a garbage bag from the waste container, especially in the case where the garbage bag is heavy. A particular problem thus results if the user, such as a child or elderly person, has insufficient strength to remove the garbage bag from the waste container.
U.S. Pat. No. 2,980,287 to Fisher discloses a lock-down floating platform mechanism for spooler troughs and doff trucks in which a spring biased platform may be latched in place by a latching mechanism so that the same can be locked in a lowered position for purposes of loading or the like. Once loaded, the platform will float depending on the load, so that unloading from a convenient level always takes place. Thus, when the platform is full, it will remain in the lowered position, and as each level of bobbins or the like are removed, the next level will rise to the top for convenient unloading.
U.S. Pat. No. 3,612,457 to Morikawa et al discloses a device for supporting a sliver can or sliver plate on a platform. The platform is positioned in a raised position to receive slivers from the processing apparatus such that the same are supported as they are coiled within the sliver can. As the load is increased, the bias on the spring beneath the platform is slowly overcome until it is in a full downward, depressed position, allowing a full sliver coil to be loaded therein. In order to move the same from place to place, a latching mechanism associated with a stop rod and projection is provided to latch the sliver plate in place.
U.S. Pat. No. 3,489,473 to Goodwin, Jr. et al discloses a textile roving can in which the top of the container takes the form of a platform which is urged upward by a coil spring. The top moves downward under the weight of sliver or roving material as the material is deposited in the can. See also U.S. Pat. No. 4,261,079 to Masini et al.
U.S. Pat. No. 2,695,209 to de Witt et al discloses a can unpacker in which the container is designed to load bags of empty cans for processing, and particularly, one level of cans at a time is unloaded. A hand crank interfaces with a chain drive to allow each successive layer of cans to be moved upwards for placement on a conveyer.
U.S. Pat. No. 2,449,892 to Gibbs discloses a similar arrangement. Specifically, the container stores articles such as trays or plates so that one level of articles is always at the top for quick removal. The platform is automatically raised to continue this process until the container is empty.
U.S. Pat. No. 3,494,503 to Kingsley discloses a storage bin in which the level of a wheeled bin for books or other articles floats so that the same may be conveniently loaded from the top until fully loaded, and a reverse operation also takes place for unloading.
Other patents which disclose related devices are U.S. Pat. No. 2,919,168 to Shivek and U.S. Pat. No. 3,357,346 to Crafoord.
However, none of these patents is related to a garbage can for household use. Rather, the above patents disclose devices which include a spring-biased platform or similar mechanism in order to selectively dispose the platform and materials contained thereon in a desired position. Specifically, some of the above references utilize a spring-biased platform which is depressed within the container during loading, and which displaces upwardly during unloading so that the goods to be unloaded are always at a convenient height. Still other ones of the above references receive sliver or roving material from a textile manufacturing operation, where it is desirable to have the platform in an upwardly extended position to accept slivers and to cause the platform to depress as the sliver material is increased, enabling a full load to be accepted while support is always provided by the platform. The structures disclosed by the prior art, however, do not provide a convenient and efficient configuration for a household garbage can.
OBJECTS AND SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a self-ejecting garbage receptacle that overcomes the problems with the aforementioned prior art.
It is another object of the present invention to provide a self-ejecting garbage receptacle that provides for automatic and strain-free removal of refuse from the container.
It is still another object of the present invention to provide a self-ejecting garbage receptacle in which the garbage receptacle is used in a manner similar to a conventional garbage receptacle, but in which the garbage can be automatically raised to remove the garbage bag from the receptacle in a strain-free manner.
It is yet another object of the present invention to provide a self-ejecting garbage receptacle for household use.
It is still another object of the present invention to provide a self-ejecting garbage receptacle in which the garbage receptacle is used in a manner similar to a conventional garbage receptacle, but in which the garbage can be automatically raised out of the receptacle and brought safely to the floor in a strain-free manner.
It is yet another object of the present invention to provide a self-ejecting garbage receptacle in which the garbage receptacle is used in a manner similar to a conventional garbage receptacle, but in which the garbage can be automatically raised out of the receptacle and transferred safely and easily to a garbage bin in a strain-free manner.
In accordance with an aspect of the present invention, a self-ejecting garbage receptacle includes container means for holding a bag containing refuse, the container means having a bottom and a side wall enclosure with an open upper end, the side wall enclosure being connected with the bottom; belt means draped in the container means for normally supporting the bag in a lowered position in the container means, the belt means having first and second opposite ends, with the first end being fixed to the side wall enclosure adjacent the open upper end; and ejector handle means for raising the belt means, the ejector handle means being connected with the second opposite end of the belt means.
The ejector handle means has a substantially jug handle configuration, is pivotally connected at one end thereof to the container means and is connected with the second opposite end of the belt means at an opposite end thereof. A hinge is provided for pivotally connecting the one end of the ejector handle means to the container means. Further, the container means includes a hook, and the ejector handle means includes latch means for engaging with the hook to hold the belt means in a raised position.
In accordance with another aspect of the present invention, a self-ejecting garbage receptacle for household use, includes container means for holding a bag containing refuse, the container means having a bottom and a side wall enclosure with an open upper end, the side wall enclosure being connected with the bottom; tray means for holding a garbage bag thereon, the tray means being positioned in the container means in substantially parallel relation to the bottom and positioned thereabove; coil spring means connected between the tray means and the bottom for biasing the tray means upwardly away from the bottom; and latch means for releasably maintaining the tray means in a lowered position in normal use in which the coil spring means is compressed, wherein release of the latch means causes the coil spring means to raise the tray means, and thereby the garbage bag, to a raised position adjacent the open upper end for removal of the garbage bag from the container means.
Specifically, the coil spring means includes a plurality of parallel coil springs connected between the tray means and the bottom, and the latch means includes a rod slidably and removably positioned over the tray means to prevent upward movement of the tray means.
In accordance with still another embodiment of the present invention, a self-ejecting garbage receptacle for household use, includes container means for holding a bag containing refuse, the container means having a bottom and a side wall enclosure with an open upper end, the side wall enclosure being connected with the bottom; foldable tray means for holding a garbage bag thereon, the tray means being positioned in the container means in a folded configuration and assuming a substantially planar configuration when released from the container means; jack means positioned within the container means and connected to the tray means for moving the tray means upwardly away from the bottom and out of the container means and for returning the tray means in the folded configuration into the container means.
The jack means includes foot pedal means extending from the container means for controlling movement of the jack means.
In accordance with yet another embodiment of the present invention, a method of self-ejecting garbage from a container having a garbage bag support therein, includes the steps of maintaining the garbage bag support in a lowered position in the container while refuse is filled in a garbage bag positioned thereon; and biasing the garbage bag support to a raised position for removal of the refuse-filled garbage bag from the container.
In accordance with a further object of the present invention, a self-ejecting garbage receptacle for household use, includes a container; means for supporting a garbage bag in the container; means for maintaining the garbage bag support means in a lowered position in the container while refuse is filled in a garbage bag positioned thereon; and means for biasing the garbage bag support means to a raised position for removal of the refuse-filled garbage bag from the container.
In accordance with another aspect of the present invention, a self-ejecting garbage receptacle for household use, includes a container for holding a bag containing refuse, the container having a bottom and a side wall enclosure with an open upper end, the side wall enclosure including a front wall, a rear wall and side walls, the side wall enclosure being connected with the bottom, each of the side walls being connected between the front and rear walls, the rear wall being taller than the front wall; a tray member movable between a first lowered position within the container and a second raised position located proximal to the open upper end, the first lowered position being parallel relative to the bottom, the second raised position being angled relative to the bottom; a belt draped in the container having first and second opposite ends, with the first end being fixed to the front wall adjacent the open upper end, the belt being supportively coupled to the tray member; a retractor connected to the container for raising the belt and thus the tray, the retractor being shaped to receive the second end of the belt and a pivotable ramp, connected to the container proximal to the open upper end of the container.
The above and other objects, features and advantages of the invention will become readily apparent from the following detailed description thereof which is to be read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal cross-sectional view of a self-ejecting garbage receptacle according to a first embodiment of the present invention, shown with the ejecting means in its lowered position;
FIG. 2 is a top plan view of the self-ejecting garbage receptacle of FIG. 1;
FIG. 3 is a longitudinal cross-sectional view of the self-ejecting garbage receptacle of FIG. 1, shown with the ejecting means in its raised position;
FIG. 4 is a longitudinal cross-sectional view of a self-ejecting garbage receptacle according to a second embodiment of the present invention, shown with the ejecting means in its lowered position;
FIG. 5 is a top plan view of the self-ejecting garbage receptacle of FIG. 4;
FIG. 6 is a longitudinal cross-sectional view of the self-ejecting garbage receptacle of FIG. 4, shown with the ejecting means in its raised position;
FIG. 7 is a longitudinal cross-sectional view of a self-ejecting garbage receptacle according to a third embodiment of the present invention, shown with the ejecting means in its lowered position;
FIG. 8 is a top plan view of the self-ejecting garbage receptacle of FIG. 7; and
FIG. 9 is a longitudinal cross-sectional view of the self-ejecting garbage receptacle of FIG. 7, shown with the ejecting means in its raised position.
FIG. 10 is a longitudinal cross-sectional view of a self-ejecting garbage receptacle according to a fourth embodiment of the present invention, shown with the ejecting means in its lowered position;
FIG. 11 is a longitudinal cross-sectional view of a self-ejecting garbage receptacle according to a fourth embodiment of the present invention, shown with the ejecting means in its raised position and shown with the garbage in its final position outside the receptacle;
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings in detail, and initially to FIGS. 1-3 thereof, a self-ejecting garbage receptacle 10 according to the present invention includes a hollow container body 12. Preferably, container body 12 is made from a tough, relatively rigid plastic material. Container body 12 includes a bottom 12a and circumferential, upstanding side walls 12b. Further, container 12 is open at the upper end 12c thereof, that is, at the upper edges of side walls 12b.
Self-ejecting garbage receptacle 10 includes an ejecting mechanism 14 for ejecting a garbage bag 15 from container 12 to permit strain-free removal of the refuse from container 12. Ejecting mechanism 14 includes a web or belt 16 of generally similar width to container body 12 and having one end 16a secured to an upstanding side wall 12b adjacent upper end 12c by any suitable means, such as adhesive, clamps or the like. Belt 16 hangs down into container 12 with a U-shaped configuration, so as to cup or hold a garbage bag therein. The opposite end 16b of belt 16 is located adjacent upper end 12c at the opposite side of container 12, and is connected with an upright actuating lever 18 that is provided to raise up belt 16, and thereby raise up garbage bag 15.
Actuating lever 18 has a generally jug handle configuration, and may include a secondary handle element 19 protruding from the upper portion of actuating lever 18 (FIGS. 1 and 3). The lower end 18a of actuating lever 18 is pivotally connected to the external surface of a side wall 12b adjacent bottom 12a, by means of a hinge assembly 20 or similar pivoting mechanism. Specifically, lower end 18a of actuating lever 18 is pivotally connected to the side wall 12b that is opposite to end 16a of belt 16, that is, to the same side wall associated with end 16b of belt 16. The opposite, upper end 18b of upright actuating lever 18 is connected with opposite end 16b of belt 16.
Thus, by pivoting actuating lever 18 downwardly about hinge 20 in the direction of arrow 21, belt 16 attached thereto is forced upwardly, as shown in FIG. 3. Since garbage bag 15 is supported on belt 16, garbage bag 15 is moved upwardly with belt 16, and thereby ejected from container 12. Of course, it is preferred that garbage bag 15 be tied prior to such operation since it will no longer be constrained by side walls 12b of container.
Further, a latch 22 in the form of an eyelet or the like, can be provided on the lower end of ejecting mechanism 14 and a hook 24 can be provided on the external surface of one side wall 12b adjacent bottom 12a for engaging latch 22. In this manner, at the end of the pivoting action of ejecting mechanism 14, latch 22 can be engaged with hook 24 to maintain belt 16 and garbage bag 15 in the position shown in FIG. 3, so as to enable strain-free removal of garbage bag 15 from container 12.
Referring now to FIGS. 4-6, a self-ejecting garbage receptacle 110 according to another embodiment of the invention will now be described in which elements corresponding to those in self-ejecting garbage receptacle 10 are identified by the same numerals, augmented by 100, and a detailed description of the common elements will be omitted herein for the sake of brevity.
In self-ejecting garbage receptacle 110, a planar tray 126 is connected to bottom 112a by means of a height adjusting mechanism 128. Specifically, height adjusting mechanism 128 is formed by a plurality of parallel coil springs 130 connected between bottom 112a and planar tray 126. Alternatively, a single large coil spring can be used. Normally, coil springs 130 are compressed and planar tray 126 is held in a lowered position by means of a latch 132 that is accessible from outside container 112 and which can be inserted through a hole 133 in container side wall 112b. In effect, latch 132 can be a pull rod or the like, as shown in FIG. 4, that can be pushed in to a restraining position above planar tray 126, so as to prevent upward movement of planar tray 126, or pulled out to permit coil springs 130 to bias planar tray 126 to a raised position. In this regard, coil springs 130 achieve a maximum height, as shown in FIG. 6, to bias planar tray 126 with a garbage bag 115 positioned thereon, to upper open end 112c of container 112.
In this regard, after a garbage bag 115 has been filled and tied, latch 132 is pulled out, whereupon coil springs 130 bias planar tray 126 to a raised position. Since garbage bag 115 is supported by planar tray 126, garbage bag 115 is also raised up to permit automatic, strain-free removal from container 112.
Although coil springs have been used as the ejecting mechanism in the second embodiment of the present invention, it will be appreciated that other types of springs can be used.
Referring now to FIGS. 7-9, a self-ejecting garbage receptacle 310 according to another embodiment of the invention will now be described in which elements corresponding to those in self-ejecting garbage receptacle 10 are identified by the same numerals, augmented by 200, and a detailed description of the common elements will be omitted herein for the sake of brevity.
Specifically, the height adjusting mechanism 228 of self-ejecting garbage receptacle 210 is formed by a jack 234 having an actuating foot lever 236 extending outwardly from container body 212 through an elongated vertical slot 212d. In this manner, by continuously pumping foot lever 236 up and down through vertical slot 212d, jack 234 can be raised. Jack 234 is only shown schematically and can include any conventional jacks. For example, a scissor jack or the like can be used along with a conversion mechanism which transforms the pumping action of foot lever 236 into a rotary action for raising the scissor jack. Alternatively, a pneumatic jack can be used which inflates the jack to raise the garbage bag 215.
A planar tray 226 is connected to the center of the jack portion that is raised. Planar tray 226 is normally in the open, planar configuration of FIG. 8. However, it can be folded into the substantially U-shaped configuration of FIG. 7 when jack 234 is positioned at the bottom 212a of container body 212. In such configuration, the folded planar tray 226 cradles the garbage bag 215, and when raised, it automatically unfolds into its natural state shown in FIGS. 8 and 9 to support garbage bag 215 thereon.
Further, although self-ejecting garbage receptacles 10, 110 and 210 are particularly useful for collecting and temporarily storing refuse and similar material, it will be appreciated that the present invention is not limited to the storage and removal of refuse for sanitary purposes, but can be used with the storage of other non-refuse type materials.
Referring now to FIGS. 10 and 11, a self-ejecting garbage receptacle 310 according to another embodiment of the invention will now be described in which elements corresponding to those in self-ejecting garbage receptacle 10 and 110 are identified by the same numerals, augmented by 300 and 200 respectively, and a detailed description of the common elements will be omitted herein for the sake of brevity.
In self-ejecting garbage receptacle 310, circumferential, upstanding side walls 312b include a front wall 342, a rear wall 344 and side walls 346 all of which have different heights. In this embodiment the front wall 342 is the shortest, while the rear wall 344 is the tallest. The two side walls 346 vary in height such that at the point of connection with the front wall 342 they have the same height as the front wall 342 and at the point of connection with the rear wall 344 they have the same height as the rear wall 344. The planar tray 326 is connected to the belt 316 by inserting the belt 316 through slots 340 in planar tray 326. It will be obvious to one skilled in the art that the tray may be connected to the belt in a number of different ways.
Self-ejecting garbage receptacle 310 includes a retractor 348 for raising the belt 316 and thus the planar tray 326. The retractor 348 preferably has a motorized take-up reel 350 which is controlled by foot peddle 352. It will be obvious to one skilled in the art that while a motorized retractor is preferable it is possible for the retractor to be manual for instance as a crank. It will also be obvious that the foot peddle control can be a hand control or any number of different switches. The retractor 348 reels in the belt 316 until the belt 316 is taught which causes the planar tray 326 to rise until the planar tray 326 is even with the open upper end 312c, thus angled relative to the bottom 312a.
Self-ejecting garbage receptacle 310 further includes a ramp 352 having a top and two sides. The ramp is connected by a hinge (not shown) to the front wall 342 proximal to the open upper end 312c. The ramp 352 is connected so that the ramp 352 may be stored in closed position adjacent the front wall 342 or used in a position which is preferably at a 140 degree angle relative to the front wall 342. It will be obvious to one skilled in the art that closed position of the ramp 352 could be resting on top of the self-ejecting garbage receptacle thus being used as a cover for the self-ejecting garbage receptacle when the ramp is being stored in its closed position. When the planar tray 326 is even with the open upper end 312c, the garbage bag 315 may be slid down the ramp 352 onto the floor or possibly into a trash bin. To prevent the garbage bag 315 from falling off the side of the ramp 352, the ramp has railings 362 connected to the top of the ramp 352 proximal to the sides of the ramp 352. To help urge the garbage bag 315 off of the planar tray 326 and onto the ramp 352, a pivotable biasing lever 364 is connected within the planar tray 326. The pivotable biasing lever 364 is manually liftable from a first closed position wherein the biasing lever 364 lies flat within the planar tray 326 to a second open position wherein the biasing lever 364 is perpendicular to the planar tray 326. When the pivotable biasing lever 364 is moved from the first closed position to the second open position it urges the garbage bag 315 onto the ramp without the operator having to touch the garbage bag 315.
There is also a ramp support 360 vertically connected to the front wall 342 proximal to one of the side walls 346. The ramp support 360 is also connected by a hinge (also not shown) so that the ramp support 360 may be located adjacent the front wall 342 or possibly the side wall 346 when the ramp 352 is in a closed position or when the ramp 352 is being used to transfer the garbage bag into a bin or the like and the ramp 352 is resting on the bin. When the garbage bag 315 is to be slid to the floor, the ramp support 360 may be positioned under the ramp 352 so that the ramp 352 is supported at an angle of about 140° degrees relative to the front wall 342.
Having described specific preferred embodiments of the invention with reference to the accompanying drawings, it will be appreciated that the present invention is not limited to those precise embodiments and that various changes and modifications can be effected therein by one of ordinary skill in the art without departing from the scope or spirit of the invention as defined by the appended claims.
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A self-ejecting garbage receptacle includes a container body for holding a garbage bag containing refuse, the container body having a bottom and a side wall enclosure with an open upper end, the side wall enclosure being connected with the bottom; a belt draped in the container body for normally supporting the bag in a lowered position in the container body, the belt having first and second opposite ends, with the first end being fixed to the side wall enclosure adjacent the open upper end; and a jug handle-shaped ejector handle for raising the belt, the ejector handle being connected with the second opposite end of the belt and being pivotally connected at one end thereof to an external surface of the container body; a hinge for pivotally connecting the ejector handle to the container body; a hook on an external surface of the container body; and a latch on the ejector handle for engaging with the hook to hold the belt in a raised position.
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FIELD OF THE INVENTION
This invention relates to electrical junction boxes and specifically to an electrical box mounting assembly for mounting a fan or light fixture to a ceiling.
BACKGROUND OF THE INVENTION
Electrical boxes are commonly mounted on ceilings for the purpose of supporting ceiling fans, light fixtures, or other electrical devices. The electrical box provides a safe enclosure to house all wiring connections. Typically, these electrical boxes are secured to the ceiling by a supporting device that spans between two adjacent ceiling joists.
Various considerations are necessary in providing supporting devices for ceiling-mounted electrical boxes. The National Electrical Code specifies a maximum weight of 80 pounds for ceiling light fixtures and a maximum weight of 70 pounds for ceiling fans. It is therefore very important that an installer use adequate load-bearing fasteners for securing the supporting device to the overhead joists. It is also important that the load be carried by the supporting device, and not by the electrical box.
A second consideration arises from the awkwardness of working overhead. Typically, when securing a supporting device and an electrical box to the overhead structure of the ceiling, several separate items must be manipulated. These include the mounting bar, the electrical box, the fasteners for securing the mounting bar to the ceiling structure, and the fasteners for mounting the electrical box to the mounting bar. Considering that the installer is typically on a ladder, this creates a challenging task for any installer. It is therefore imperative that all parts necessary for a successful installation are on hand for the installer.
A third consideration is that the support device must be matched to an electrical box. Many supporting devices are meant to accommodate most commercial electrical boxes. This typically requires complex arrangements on the supporting device to accommodate a variety of boxes.
A further consideration arises as a result of the various different types of ceilings, each of a different thickness. It should be easy for an installer to mount the support device correctly on the overhead joists to position the bottom of the electrical box flush with the ceiling, regardless of the thickness of the ceiling.
Many supporting devices for ceiling fans and fixtures include an arrangement to temporarily secure the device to the ceiling joists including U.S. Pat. No. 5,934,631 to Becker, et al., U.S. Pat. No. 5,954,304 to Jorgensen, U.S. Pat. No. 5,938,157 to Reiker, and U.S. Pat. No. 6,098,945 to Korcz, and U.S. Pat. No. 6,332,597 to Korcz et al.
Although all of the above supporting devices include an arrangement for temporarily fastening the supporting device to overhead joists to free up an installer's hands, they are still not completely satisfactory for simplifying the remainder of the task for installing the electrical box and the light fixture or fan to the supporting device.
SUMMARY OF THE INVENTION
The invention is an adjustable mounting bar and electrical box assembly for hanging a light fixture, fan, or other electrical device from a ceiling. All hardware required for mounting the electrical device is included with the assembly. The adjustable mounting bar includes sliding tubular members with end flanges for spanning between adjacent overhead joists. An electrical box is connected to the tubular members by a clamp and outer clamping fasteners, which can be loosened to adjust the length of the adjustable mounting bar. The end flanges include penetrable tabs that can be driven into the overhead joists to temporarily secure the adjustable mounting bar to the joists and thereby free the installer's hands. The outer face of the end flanges include a series of rows of slots arranged horizontally thereon and forming a plurality of bend lines. To accommodate ceiling coverings of various thickness, the end flanges can be bent outwards at the proper bend line to position the lower end of the electrical box flush with the ceiling surface. Load bearing bar fasteners threadably engaged in temporary storage receptacles in the sliding tubular members are removed therefrom and fastened through the end flanges to securely fasten the mounting bar to the joists. Load bearing device fasteners threadably engaged in temporary storage receptacles in the electrical box are removed therefrom and driven into receptacles in the clamp to secure the electrical device to the mounting bar. Oversize openings are provided in the top wall of the electrical box to ensure that the entire suspended load is borne by the clamp and mounting bar and not the electrical box.
OBJECTS AND ADVANTAGES
The electrical box mounting assembly of the present invention provides a complete mounting assembly for mounting an electrical device to a ceiling, including all of the required fastening hardware. All of the installation hardware that is required to complete the task is provided as a part of the mounting assembly, including all required fasteners.
An additional advantage is that the required fasteners are held securely in the electrical box mounting assembly in temporary storage receptacles. The temporary storage receptacles provide an advantage in that the fasteners are held securely in the assembly until they are ready to be used. The required fastening hardware is therefore on hand for installation at the time it is required. By freeing up an installer's hands, the task of mounting an electrical device to a ceiling is therefore greatly simplified and the installation time greatly reduced. Additionally, by having all of the required fastening hardware on hand, the installer is not burdened by the task of locating appropriate fasteners at the appropriate time.
The electrical box mounting assembly also provides the advantage that the entire load is supported by the supporting bars and the clamp, and not by the electrical box itself.
A further advantage is that the fastening hardware, while in storage in the temporary storage receptacles, does not extend beyond the outer periphery of the bars and end flanges.
These and other objects and advantages of the present invention will be better understood by reading the following description along with reference to the drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a preferred embodiment of an electrical box mounting assembly according to the present invention including an adjustable mounting bar and an electrical box assembly.
FIG. 2 is a bottom view of two tubular members that will be fitted together to form an adjustable mounting bar according to the present invention.
FIG. 3 is a side view of the two tubular members of FIG. 2 .
FIG. 4 is a bottom view of the two tubular members of FIG. 3 after they are fitted together to form the adjustable mounting bar of the present invention.
FIG. 5 is a cross-sectional view of the adjustable mounting bar taken along line 5 — 5 of FIG. 4 .
FIG. 6 is a perspective view of the electrical box portion of the electrical box mounting assembly of FIG. 1 .
FIG. 7 is a bottom view of the electrical box shown in FIG. 6 .
FIG. 8 is a sectional view of the electrical box taken along line 8 — 8 of FIG. 7 .
FIG. 9 is a perspective view of an outer clamping member that forms a portion of a clamping arrangement in the adjustable mounting bar and electrical box assembly of the present invention.
FIG. 10 is a perspective view of an inner bar that forms a portion of a clamping arrangement in the adjustable mounting bar and electrical box assembly of the present invention.
FIG. 11 is a cross-sectional view of the adjustable mounting bar taken along line 11 — 11 of FIG. 12 and depicting the clamping arrangement portion of the present invention.
FIG. 12 is a bottom view of the adjustable mounting bar and electrical box assembly of FIG. 1 .
FIG. 13 is an end view of the adjustable mounting bar taken along line 13 — 13 of FIG. 3 .
FIG. 14 is a side view of the adjustable mounting bar and electrical box assembly of FIG. 1 , overhead joists, and a ceiling fixture in position to be attached thereto on a ceiling with a thin ceiling cover.
FIG. 15 is a side view of the adjustable mounting bar and electrical box assembly of FIG. 1 , overhead joists, and a ceiling fixture in position to be attached thereto on a ceiling with a thick ceiling cover.
TABLE OF NOMENCLATURE
The following is a listing of part numbers used in the drawings along with a brief description:
Part Number
Description
20
electrical box mounting assembly
22
adjustable mounting bar
24
inner tubular member
26
outer tubular member
28
electrical box
30
outer end of inner tubular member
32
inner end of inner tubular member
34
outer end of outer tubular member
36
inner end of outer tubular member
38
bottom sides of tubular members
40
longitudinal slot
42
lip
44
end flange
46
top wall of electrical box
48
top surface of top wall
50
side walls of electrical box
52
bottom edge of side walls of electrical box
54
knockout areas
56
clamp arrangement
58
inner bar
60
outer clamping member
62
outer aperture in inner bar
64
inner aperture in inner bar
66
middle aperture in outer clamping member
68
inner threaded bore in outer clamping member
70
planar portion of outer clamping member
72
upturned edge
73
first fastener
74
outer clamping fastener
76
oversized opening in top wall of electrical box
78
receptacle
80
aperture in flange
82
inner face of flange
83
outer face of flange
84
V-shaped tab
86
joist
88
first temporary storage receptacle
90
second temporary storage receptacle
92
bar fastener
94
device fastener
98
outer edge of flange
100
mounting ring
102
electrical device
104
bent over portion of bottom edge of electrical box
106
alignment apertures
108
side portion of rectangular cross section
110
top surface of lip
111
inner channel within tubular members
112
aperture in top wall of electrical box for first fastener
114
aperture in top wall of electrical box for device fastener
116
grounding aperture
118
grounding screw
120
outer surface of end flange
122
row of apertures or slots
124A
first bend line
124B
second bend line
124C
third bend line
126
indicia
128
outward facing seat
130
ceiling cover
132
bottom edge of end flange
134
line connecting bottom edge of end flanges
136
line level with ceiling surface
140
positioning arrangement
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1 , there is depicted an electrical box mounting assembly 20 for securing an electrical device (not shown), such as a light fixture or a fan, to a ceiling. The electrical box mounting assembly 20 includes an adjustable mounting bar 22 including an inner 24 and an outer 26 tubular member, and an electrical box 28 .
Referring to FIGS. 2–5 , the inner tubular member 24 has an outer end 30 and an inner end 32 . The outer tubular member 26 also has an outer end 34 and an inner end 36 . Both of the tubular members 24 , 26 have rectangular cross sections.
As shown in FIG. 5 , the inner tubular member 24 has a smaller rectangular cross section than the outer tubular member 26 , thereby enabling the inner tubular member 24 to be received in and slide with respect to the outer tubular member 26 .
With reference to FIG. 2 , the bottom sides 38 of each tubular member 24 , 26 include longitudinal slots 40 . Lips 42 surround the slots 40 and extend longitudinally along the bottom sides 38 . Each of the tubular members 24 , 26 include an end flange 44 on their outer ends 30 , 34 .
Referring to FIGS. 6–8 , the electrical box 28 used with the electrical box mounting assembly of the present invention includes a top wall 46 having a top surface 48 and side walls 50 having a bottom edge 52 . The electrical box 28 may include knockout areas 54 which may be later removed as desired to allow for passage of wiring there through.
With reference to FIGS. 9–10 , a clamp arrangement 56 is depicted. The clamp arrangement 56 includes an inner bar 58 and an outer clamping member 60 . The inner bar 58 includes outer 62 and inner 64 apertures that align respectively with middle 66 apertures and inner threaded bores 68 in the outer clamping member 60 . Outer clamping member 60 includes a planar portion 70 and upturned edges 72 at a 90 degree angle to the planar portion 70 .
Referring to FIGS. 11 and 12 , the outer clamping member 60 is secured to the top surface 48 of the electrical box 28 by first fasteners 73 through aperture 112 in the top wall 46 of the electrical box 28 and secured into the inner threaded bores 68 in the outer clamping member 60 . Outer clamping fasteners 74 connect the outer clamping member 60 to the inner bar 58 with the lips 42 of the bottom side 38 of the tubular members 24 , 26 sandwiched there between. The inner bar 58 therefore is disposed within the inner tubular member 24 and rests on the lips 42 of the inner tubular member 24 . With the outer clamping fasteners 74 loosely holding the outer clamping member 60 to the inner bar 58 , the inner tubular member 24 can be easily slid within the outer tubular member 26 thereby adjusting the adjustable mounting bar 22 to the desired length. Since the outer clamping member 60 has already been secured tightly to the electrical box 28 , once the adjustable mounting bar 22 has been adjusted to the desired length, the electrical box 28 can be adjusted to the desired position on the mounting bar 22 whereupon the outer clamping fasteners 74 can be tightened into the inner bar 58 to lock the adjustable mounting bar 22 to the desired length and also lock the electrical box 28 in the desired position. Two outer clamping fasteners 74 are typically used. The top wall 46 of the electrical box 28 includes oversized openings 76 sized larger than the head of the outer clamping fasteners 74 , therefore allowing the electrical box 28 , after initial mounting, to be removed from the adjustable mounting bar 22 without changing the length of the bar 22 . The oversized openings 76 also insure that all of the weight of a suspended device is borne by the inner bar 58 and the tubular members 24 , 26 and not by the electrical box 28 , which, as a result of the oversized openings 76 , escapes contact with the outer clamping fastener 74 and therefore does not support any of the suspended load. As shown in FIG. 9 , the outer clamping member 60 further includes receptacles 78 , the function of which will be explained herein.
Referring to FIG. 1 , the end flanges 44 of the inner 24 and outer 26 tubular members include apertures 80 , an inner face 82 , and a V-shaped tab 84 bent from the inner face 82 such that the tab 84 can be later hammered outwards to temporarily secure the adjustable mounting bar 22 to the joists (not shown).
A distinguishing feature of the preferred embodiment of the electrical box mounting assembly 20 is the inclusion of prepackaged fasteners to simplify its installation. The prepackaged fasteners are held in temporary storage receptacles to make them readily available to the installer at the time of installation. As can be readily appreciated by anyone who has installed an overhead light fixture or fan, the fact that all the work is overhead and the installer is typically on a ladder, makes the installation challenging. One of the most difficult aspects of the installation is freeing ones hands to obtain the various fasteners, making sure to obtain the correct fastener, handling the fastener and screwdriver, and inserting the fastener while keeping the fan or light fixture in the proper position. To ease the installation task the electrical box mounting assembly 20 therefore includes a first temporary storage receptacle 88 near the outer ends 30 , 34 of the tubular members 24 , 26 as shown in FIG. 3 and two or more second temporary storage receptacles 90 in the top wall 46 of the electrical box 28 as shown in FIGS. 6–8 . Prepackaged fasteners, as shown in FIG. 1 , are stored in the temporary storage receptacles 88 , 90 and include one or more bar fasteners 92 secured in the first temporary storage receptacles 88 and a device fastener 94 secured in the second temporary storage receptacle 90 .
The electrical box mounting assembly 20 is typically supplied as shown in FIG. 1 but with the adjustable mounting bar 22 adjusted to its shortest length. As shown in FIG. 11 , the outer clamping fasteners 74 are typically secured tightly to the inner bar 58 to lock the electrical box mounting assembly 20 to its shortest length. As supplied, the electrical box 28 , referring to FIG. 1 , is held tightly to the adjustable mounting bar 22 , the bar fasteners 92 are held tightly in the first temporary storage receptacles 88 , and the device fasteners 94 are held tightly in the second temporary storage receptacles 90 . The device fasteners 94 are typically screws and the second temporary storage receptacles 90 are typically threaded bores. The device fasteners 94 are typically threaded into the second temporary storage receptacles 90 to a position in which the heads of the device fasteners 94 reside within the box and do not extend beyond a plane intersecting the bottom edge 52 of the electrical box 28 . The bar fasteners 92 typically do not extend beyond the outer edge 98 of the end flanges 44 . The electrical box mounting assembly 20 is therefore supplied in the smallest profile possible, with the bar fasteners 92 and device fasteners 94 not extending beyond the lateral extent of the electrical box 28 or the end flanges 44 . For shipment, storage, and sale the electrical box mounting assembly 20 as supplied can be easily packaged within a rectangular packaging container without any fear of the prepackaged fasteners 92 , 94 snagging or catching on the container or of loosening or dislodging from the first 88 and second 90 temporary storage receptacles. Alternatively, the electrical box 28 could be packaged and sold separately of the adjustable mounting bar 22 , for example, to allow the consumer to choose an electrical box of a specific depth or shape, in which case the adjustable mounting bar 22 with the bar fasteners 92 temporarily stored therein would be packaged separately of the electrical box 28 with the device fasteners temporarily 94 stored therein. The explanation of the operation of the electrical box mounting assembly 20 that follows assumes the electrical box mounting assembly 20 is sold as a unit, with the electrical box 28 temporarily secured to the adjustable mounting bar 22 .
To place the electrical box mounting assembly 20 in operation, a suitable location is found on a ceiling. Referring to FIG. 1 , the outer clamping fasteners 74 are loosened, allowing the adjustable mounting bar 22 to be adjusted in length and further allowing the electrical box 28 to be slid along the length of the adjustable mounting bar 22 to the desired location.
As shown in FIG. 14 , the adjustable mounting bar 22 is adjusted to accommodate the distance between adjacent overhead joists 86 and the electrical box 28 is slid to the desired position on the mounting bar 22 . The outer clamping fasteners 74 are then tightened to lock the electrical box 28 to the mounting bar 22 and to lock the adjustable mounting bar 22 to its desired length to span the joists 86 . At this point in the installation procedure, the installer's hands are free and all of the required installation hardware is contained with the electrical box mounting assembly 20 in the form of the prepackaged fasteners 92 , 94 . The installer then lifts the electrical box mounting assembly 20 into the desired position between the joists 86 and hammers the V-shaped tabs 84 into the joists 86 to temporarily hold the mounting assembly 20 to the joists. The installers hands are then free to remove the bar fasteners 92 one at a time and secure them through the flange apertures 80 and into the joists 86 . As shown in FIG. 1 , a most preferred embodiment of the electrical box mounting assembly 20 includes four bar fasteners 92 . The bar fasteners 92 are load bearing fasteners that are rated to hold an 80 pound ceiling light fixture or a 70 pound ceiling fan as specified by the National Electrical Code. After the bar fasteners 92 have been installed, the installer's hands are again free to proceed with the installation. The device fasteners 94 , which are held tightly in the second temporary storage receptacles 90 , may then be removed, the mounting ring 100 of an electrical device, such as a ceiling fan or light fixture 102 , lifted in alignment with the bottom edge 52 of the electrical box 28 , and the device fasteners 94 threaded into the receptacles 78 (see FIG. 7 ) to suspend the electrical device 102 from the electrical box mounting assembly 20 . The receptacles 78 are typically threaded bores within the outer clamping member 60 to accept the device fasteners 94 .
Referring to FIGS. 6 and 9 , the bottom edge 52 of the electrical box 28 includes bent over portions 104 having alignment apertures 106 therein, the alignment apertures 106 situated to be in vertical alignment with the receptacles 78 in the outer clamping member 60 .
With reference to FIG. 12 , prior to tightening the device fasteners 94 , wiring connections (not shown) can be completed between the housing electrical supply and the electrical device 102 . Once wiring connections are completed, the device fasteners 94 are tightened to secure the electrical device 102 to the electrical box mounting assembly 20 .
With reference to FIG. 5 , it should be noted that the rectangular cross sections of the tubular members 24 , 26 include side portions 108 . The lips 42 of both the inner 24 and outer 26 tubular members include a top surface 110 that is smooth to allow the inner tubular member 24 to slide smoothly upon the outer tubular member 26 and to also allow the inner bar (not shown) to slide smoothly upon the lips 42 of the inner tubular member 24 . As shown in FIG. 5 , the top surface 110 of the lips 42 , which face the inner channel 111 within the tubular members 24 , 26 , are at a non-oblique angle to the side portions 108 .
Referring to FIG. 12 , it is critical that several dimensions and materials of construction are maintained within specifications to support the weight of the electrical box mounting assembly 20 and the electrical device 102 suspended there from. The inner 24 and outer 26 tubular members, the electrical box 28 , the outer clamping member 60 , and the inner bar 58 are typically constructed from steel to resist torsional bending and strain from the suspended electrical device 102 . The steel pieces are typically zinc-plated to render them rust resistant. The wall thickness of the tubular members 24 , 26 is typically at least 0.038 inch. The inner bar 58 is at least 0.120 inch thick. The outer clamping member 60 is at least 0.050 inch thick.
With reference to FIGS. 1 and 14 , the end flanges 44 are preferably at a 90 degree angle to the tubular members 24 , 26 and the flanges 44 on each tubular member 24 , 26 are of equal lengths. The bar fastener 92 will be load-bearing and is preferably a self-tapping machine screw no smaller than a #10 and no less than 1 inch in length. To accommodate the self-tapping machine screw bar fastener 92 , the first temporary storage receptacle 88 is preferably a circular aperture with a diameter of 0.172 inch. The size of the device fastener 94 would vary in length depending on the size of the electrical box 28 , but is preferably a 10-32 screw no less than 2.5 inches in length for an electrical box with a side wall of length 1.590 inch. The second temporary storage receptacles 90 are preferably threaded bores in the top wall 46 of the electrical box 28 threaded to match the threads on the device fastener 94 .
Referring to FIGS. 6–8 , the top surface 48 of the electrical box 28 typically is planar. The preferred embodiment of the top wall 46 includes the second temporary storage receptacles 90 which are threaded bores that will accept device fasteners 94 , two apertures 112 that will accept first fasteners 73 , oversized openings 76 to accommodate the outer clamping fasteners 74 , apertures 114 to accommodate the device fasteners 94 when they are moved from the second temporary storage receptacles 90 to their receptacles, and a grounding aperture 116 which is a threaded bore to accept a grounding screw 118 .
Referring to FIGS. 12 and 13 , the end flanges 44 of the adjustable mounting bar 22 include an outer surface 120 that includes a plurality of rows of parallel apertures or slots 122 . Each row of apertures 122 defines a separate bend line 124 A, 124 B, 124 C. Indicia 126 are marked on the outer surface 120 of the end flanges 44 to indicate the thickness of ceiling covering material that are typically encountered in building construction. The indicia 126 correspond to a given thickness of ceiling covering material. Each row of parallel apertures 122 provides a bend line 124 A, 124 B, or 124 C at which the end flange 44 can be bent outwardly to provide an outward facing seat 128 (see FIG. 15 ) for properly positioning the electrical box mounting assembly 20 for a given thickness of ceiling cover. For example, FIG. 14 depicts the installation of the electrical box mounting assembly 20 to two adjacent joists 86 that will be covered with ½″ thick ceiling cover 130 . For positioning the electrical box mounting assembly 20 on joists 86 that will receive a ½″ thick ceiling covering 130 , the end flanges 44 are kept intact and the bottom edge 132 of the end flange 44 (see FIG. 13 ) is aligned with the bottom of the joists 86 . The bottom edge 52 of the sidewalls 50 of the electrical box 28 extend ½″ below the line 134 connecting the bottom edge 132 of the end flanges 44 . Therefore, positioning the bottom edge 132 of the end flanges 44 level with the bottom of the joists 86 positions the bottom edge 52 of the electrical box 28 level with the lower surface of the ½″ thick ceiling cover 130 , denoted by line 136 in FIG. 14 .
As an alternative example for a different thickness of ceiling cover, FIG. 15 depicts the installation of the electrical box mounting assembly 20 to two adjacent joists 86 that will be covered with ¾″ thick ceiling cover 130 . For positioning the electrical box mounting assembly 20 on joists 86 that will receive a ¾″ thick ceiling covering 130 , the end flanges 44 are bent outwards at the “A” bend line 124 A. The resulting outward facing seat 128 on each of the end flanges 44 is placed flush against the bottom of each of the joists 86 . Positioning the outward facing seat 128 of the end flanges 44 flush against the bottom of the joists 86 positions the bottom edge 52 of the electrical box 28 level with the lower surface of the ¾″ thick ceiling cover 130 , denoted by line 136 in FIG. 15 . In a similar manner, bending the end flanges 44 outwardly at the “B” bend line 124 B will position the bottom edge 52 of the electrical box 28 level with a 1″ thick ceiling and bending the end flanges 44 outwardly at the “C” bend line 124 C will position the bottom edge 52 of the electrical box 28 level with a 1″ thick ceiling. The bend lines 124 A, 124 B, 124 C therefore provide a positioning arrangement 140 (see FIG. 13 ) that allows easy positioning of the electrical box mounting assembly 20 for a given thickness of ceiling cover 130 .
Having thus described the invention with reference to a preferred embodiment, it is to be understood that the invention is not so limited by the description herein but is defined as follows by the appended claims.
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An adjustable mounting bar and electrical box assembly for hanging a light fixture, fan, or other electrical device from a ceiling. All hardware required for mounting the electrical device is included with the assembly. The adjustable mounting bar includes sliding tubular members with end flanges for spanning between adjacent overhead joists. An electrical box is connected to the tubular members by a clamp and outer clamping fasteners, which can be loosened to adjust the length of the adjustable mounting bar. The end flanges include penetrable tabs that can be driven into the overhead joists to temporarily secure the adjustable mounting bar to the joists and thereby free the installer's hands. The outer face of the end flanges include a series of rows of slots arranged horizontally thereon and forming a plurality of bend lines. To accommodate ceiling coverings of various thickness, the end flanges can be bent outwards at the proper bend line to position the lower end of the electrical box flush with the ceiling surface. Load bearing bar fasteners threadably engaged in temporary storage receptacles in the sliding tubular members are removed therefrom and fastened through the end flanges to securely fasten the mounting bar to the joists. Load bearing device fasteners threadably engaged in temporary storage receptacles in the electrical box are removed therefrom and driven into receptacles in the clamp to secure the electrical device to the mounting bar. Oversize openings are provided in the top wall of the electrical box to ensure that the entire suspended load is borne by the clamp and mounting bar and not the electrical box.
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This application claims priority of PCT application PCT/CH2007/000475 having a priority date of Sep. 28, 2006, the disclosure of which is incorporated herein by reference.
TECHNICAL FIELD
The invention relates to a shedding apparatus for a weaving machine, in particular for a ribbon weaving machine.
BACKGROUND OF THE INVENTION
Shedding apparatuses for weaving machines which have a heddle apparatus and a heddle frame are known in principle from numerous documents. WO-A-98/24955 discloses a weaving machine in which the dragging element for dragging the warp threads of a weaving machine and comprising for example a heddle frame is clamped between two springs. There, the dragging element oscillates and a holding device is capable of stopping the oscillation for a certain time, and so forming a shed during the weft insertion. The holding device from WO-A-98/24955 is intended to be controllable by means of a control unit. Permanent magnets which can be influenced by electromagnets have already been proposed for this.
However, the configuration with the two springs of WO-A-98/24955 takes up a relatively large space, as the drawings there also show. Furthermore, the controlled holding device is complicated, even if it takes the form of permanent magnets, because of the electromagnetic influence on the permanent magnets.
SUMMARY OF THE INVENTION
The object of the invention is to improve a shedding apparatus for weaving machines which have a heddle apparatus and a heddle frame.
The object is achieved by a shedding apparatus. In this case, the measures of the invention firstly result in a very small space requirement. The kinetic energy of the heddle motion can be provided for the most part by a tension/compression spring. The tension/compression spring is in this case set up in such a way that, in an upper position and in a lower position, it respectively provides a great potential energy as a force which moves the heddle in the direction of a middle position. The middle position is preferably characterized in that, in this position, no potential energy is emitted by the spring, but instead the heddle has a maximum speed, and is then moved further into the other position respectively, that is to say the lower position or the upper position, the tension/compression spring then being able to take up the kinetic energy of the heddle in the form of potential energy. In order, however, to make a controlled heddle motion possible, and optional pausing in the upper position or lower position, magnetically acting holding means are respectively provided in the upper position and the lower position, means which stop the heddle motion and hold the heddle in the respective position. In order to make a controlled motion possible, an optionally switchable, electric linear motor is additionally provided. Together with the spring force, it overcomes the holding force of the holding means and can therefore free the heddle from its held position. In principle, the linear motor is therefore intended for releasing the heddle from the holding means and initiating the heddle moving operation. Furthermore, the linear drive means serves the purpose of compensating for energy losses and adapting the heddle apparatus to changing operating conditions. The heddle apparatus is controlled exclusively by the control of the linear motor.
It is advantageous if at least 75% of the kinetic energy is taken from the tension/compression spring, and the linear motor provides at most 25% of the kinetic energy.
An advantageous refinement of the invention is obtained if the holding means are formed in an uncontrolled manner as permanent magnets which interact with magnetic counter-holders.
A form is particularly advantageous, since the entry of the magnetically acting holding elements, which are advantageously formed from iron, into the effective range of the coil magnets avoids direct contact, resulting in particularly low-noise running of the shedding apparatus.
Advantageously, no force is exerted on the heddle frame in a third shed position, between the upper shed position and the lower shed position.
It is particularly advantageous with respect to the allocation of space and the dynamic properties of the system if the tension/compression spring is formed as a leaf spring, and thereby formed in an ring-like manner. It goes without saying that in this context a ring does not have to be interpreted as a circular formation. Rather, the term “ring-like” is to be understood as meaning closed formations such as round, oval, elliptical or similarly formed springs, which are possibly suitable for accommodating components within them for the purpose of reducing the space requirement. In one particular embodiment, it is provided that the spring force to be applied is divided between two springs, which are arranged at the ends of the heddle apparatus. In order to eliminate the transverse forces, it is advantageous if the heddle apparatus is formed symmetrically with respect to its center axis.
An advantageous shedding apparatus has a number of heddle apparatuses arranged in a group. It is particularly advantageous in this respect if the tension/compression springs are arranged alternating with one another, one or more on top and one or more underneath.
In the case of the embodiment with stop magnets and magnetic counter-holders, it is more advantageous if they heddle apparatus has a support frame that is connected to the heddle frame and encloses a fixed block part. In this case, the stop magnets and the magnetic counter-holders are arranged on the upper and lower parts of the support frame or on the upper side and underside of the block part, respectively. If the block part then has a respectively adjustable upper part and lower part, these can be adjusted according to the inclination of the running of the warp threads of the upper shed and the lower shed, respectively.
It is advantageous if the linear motor has a flat coil, which is arranged in the plane of the heddle frame.
The aforementioned elements to be used according to the invention, as well as those claimed and described in the following exemplary embodiments, are not subject to any particular conditions by way of exclusion in terms of their size, shape, use of material and technical design, with the result that the selection criteria known in the respective field of application can be used unrestrictedly.
BRIEF DESCRIPTION OF THE DRAWINGS
Exemplary embodiments of a shedding apparatus for weaving machines with a heddle apparatus and a heddle frame are described in more detail below on the basis of the drawings, in which:
FIG. 1 shows the weaving region of a weaving machine with a shedding apparatus according to a first embodiment of the present invention, in side view;
FIG. 2 shows a single heddle apparatus of the shedding apparatus from FIG. 1 in a view from the front;
FIG. 3 shows a force diagram for the sequences of movements of the heddle motion of the apparatus according to FIGS. 1 and 2 ;
FIG. 4 shows a shedding apparatus with a heddle apparatus according to an alternative embodiment of the present invention in a perspective view;
FIG. 5 shows an enlarged representation of a detail from FIG. 4 ;
FIG. 6 shows the weaving region of a weaving machine with a shedding apparatus according to a further embodiment of the present invention, in side view; and
FIG. 7 shows a single heddle apparatus of the shedding apparatus from FIG. 6 in a view from the front.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A first exemplary embodiment for carrying out the present invention is represented in FIGS. 1 and 2 .
FIG. 1 shows the diagram of the weaving region of a weaving machine in side view. A shedding apparatus with a number of heddle apparatuses 2 serves the purpose of opening warp threads 50 to form a weaving shed with an upper shed and a lower shed, into which a weft insertion element inserts a weft thread with every change of shed. A weaving reed 42 beats up the inserted weft thread at the edge of the fabric produced.
As FIG. 2 reveals, each heddle apparatus 2 includes a heddle frame 4 , with heddle supports 6 , on which heddles 40 for guiding the warp threads 50 are arranged. In the present example, the heddles 40 are grouped together in four groups for four weaving locations of a ribbon weaving machine. The heddle frame 4 is connected to a linear motor 12 by way of a heddle connector 8 . In FIG. 1 , the heddle apparatus 2 has at the top and bottom and upper, fixed stop magnet 24 and a lower, fixed stop magnet 26 , which in the state in which they are brought into close proximity, interact with the respective magnetic counter-holders 30 and 32 , which are assigned to the moved heddle frame 4 .
In FIG. 2 , the heddle apparatus 2 is represented from the front. Shown in FIG. 2 as an addition to the representation in FIG. 1 is a leaf spring 14 , which is formed in a ring-like manner and assists a heddle motion in the vertical direction. One particular feature of this exemplary embodiment is that here the lower stop magnet 26 is accommodated within the leaf spring 14 and the corresponding lower magnetic counter-holder 32 is mounted on the leaf spring 14 . The stop magnet 24 is mounted on the spring holder 20 , which holds the leaf spring. In this exemplary embodiment, the upper magnetic counter-holder 30 is attached to the heddle frame 4 , while the upper stop magnet 24 is fixedly mounted.
The heddle apparatus is formed symmetrically with respect to a center line M, in order to avoid transverse forces.
The operating mode of the shedding apparatus is now described below, according to the exemplary embodiment described above. The heddle frames 4 with the heddle supports 6 are raised and lowered for the purpose of shedding. As the driving means for this movement, the spring drive, in the exemplary embodiment the leaf spring 14 arranged on the spring holder 20 , and a linear motor 12 interact. The linear motor 12 comprises a flat coil 34 and an upper coil magnet 36 and a lower coil magnet 38 , which are arranged on the heddle connector 8 . During the lifting or lowering movement, the greatest proportion of energy is applied by the spring drive. However, the movement is initiated by the linear motor 12 , as described below.
By means of the upper stop magnet 24 or the lower stop magnet 26 and the respective magnetic counter-holders 30 and 32 , the heddle frame 4 is securely held in the upper end position or the lower end position—which correspond to the upper shed position and the lower shed position of the warp threads of a weaving shed—as long as the linear motor 12 is not in operation. This is achieved by the stop magnets 24 and 26 , which are formed as permanent magnets, having a greater holding force than the restoring force of the leaf spring 14 in the case of the deflection to the end positions. It should be pointed out that the holding force of the permanent magnets 24 and 26 has a short range and is therefore only relevant at all in the vicinity of the magnetic counter-holders 30 and 32 , and consequently only in or in the vicinity of the respective end position.
In order then to set the heddle frame 4 in motion, in order therefore to initiate a shedding motion from the upper end position into the lower end position or from the lower end position into the upper end position, the linear motor 12 is put into operation. The sum of the effective forces of the linear motor 12 and the spring force of the leaf spring 14 in the deflected state, that is to say in one of the end positions, is greater than the holding force of the permanent magnets 24 and 26 , respectively.
When the holding force of the permanent magnets 24 and 26 is overcome, the motion of the heddle is brought about for the most part by the spring force of the leaf spring 14 , and the linear motor 12 moves along with this motion without significantly contributing to it. When the other end position is reached, that is to say for example when the lower stop magnet 26 enters the effective range of the lower magnetic counter-holder 32 , the renewed end position is reached and the leaf spring 14 remains deflected, since the force of the permanent magnet 26 in this position is greater than the restoring force of the leaf spring 14 , and the linear motor 12 does not assist the latter.
The force profile of the motion is shown in the diagram of forces in FIG. 3 . In the exemplary embodiment mentioned here, the ring-like leaf spring 14 is operated in the linear range, so that the spring force diagram 100 can be represented by a straight line. The spring force is assisted by the warp thread force 106 only insignificantly, so that the warp thread force 106 plays no part here. The stop magnet diagram 102 clearly shows the short range of the magnetic forces, which only act when the stop magnets 24 , 26 are in the direct vicinity of the magnetic counter-holders 30 , 32 and an end position has been assumed. The diagram of coil forces 104 of the linear motor 12 has a constant force in the operating mode described here, which may be directed in one direction or the other, depending on polarity.
In the exemplary embodiments described here, the linear motor 12 is formed in such a way that, in addition to the upper position and the lower position, a middle position of the heddle can be assumed, and the heddle can be moved from this middle position into the upper position or into the lower position.
This operating mode has the purpose that a rest position can be assumed, a position in which the leaf spring 14 does not exert any force on the heddle frame. The heddle apparatus is controlled exclusively by means of the linear motor, which for this purpose is connected to a control unit of a weaving machine in a way that is not represented in any more detail.
FIG. 4 and FIG. 5 show a shedding apparatus according to a second exemplary embodiment, comprising a multiplicity of heddle apparatuses 2 1 - 2 6 with in each case a heddle frame 4 according to a preferred exemplary embodiment. Of the heddle frames 4 , only the heddle supports 6 are represented here. In the embodiment that is shown in FIGS. 4 and 5 , the heddle frames 4 are connected at the top or bottom by means of a heddle connector 8 to a support frame 10 , which for its part is connected to a linear motor 12 and then further connected to a leaf spring 14 or 16 formed in a ring-like manner. The lower leaf springs 14 are attached to a lower, fixed shedding block 18 with a spring holder 20 , whereas the upper leaf springs 16 are attached to an upper, fixed shedding block 22 , likewise with a spring holder 20 . The leaf springs 14 and 16 act in turn as tension/compression springs and the spring arrangement and adjustment is chosen such that the heddle frames 4 are in the middle shed position in the rest position of the springs 14 , 16 .
In the support frames 10 , the magnetic counter-holders 30 and 32 are respectively attached from the inside at the top and bottom. The lower shedding block 18 and the upper shedding block 22 respectively have at the upper and lower ends a block part 28 , to which stop magnets 24 and 26 are attached. In the present exemplary embodiment, the stop magnets 24 and 26 are arranged in an inclined plane. In this respect, the inclinations are adjustable according to the desired inclination of the running of the warp thread of the upper shed and the lower shed, respectively.
The linear motors 12 have in each case electrical conductors 46 , which are led to a connection plate 48 , by way of which the linear motors 12 can be connected to a control unit.
A further exemplary embodiment for carrying out the present invention is represented in FIGS. 6 and 7 .
FIG. 6 shows the diagram of the weaving region of such a weaving machine according to a further exemplary embodiment in side view. The shedding apparatus with the heddle apparatuses 2 corresponds to the first exemplary embodiment and is not described any further here.
In FIG. 6 , the heddle apparatus 2 respectively has above and below the flat coil 34 of the linear motor 12 an upper and lower magnetically acting holding element 130 , 132 —in the exemplary embodiment made of iron—which alternately enter the magnetic field of the coil magnets 26 and 38 and form with them upper and lower holding means 130 , 36 ; 132 , 38 .
The heddle apparatus is in turn formed symmetrically with respect to a center line M, in order to avoid transverse forces.
By means of the upper holding means 130 , 36 or the lower holding means 132 , 38 , the heddle frame 4 is in turn securely held in the upper end position or the lower end position—which correspond to the upper shed position and the lower shed position of the warp threads of a weaving shed—as long as the linear motor 12 is not in operation. This is achieved by the holding means having a greater holding force than the restoring force of the leaf spring 14 in the case of the deflection to the end positions. It should be pointed out that the holding force of the holding means has a short range and is therefore only relevant at all in the state in which it has entered the range of the counter-element, and consequently only in or in the region of the respective end position.
In order then to set the heddle frame 4 in motion, in order therefore to initiate a shedding motion from the upper end position into the lower end position or from the lower end position into the upper end position, in this exemplary embodiment too the linear motor 12 is put into operation. The sum of the effective forces of the linear motor 12 and the spring force of the leaf spring 14 in the deflected state, that is to say in one of the end positions, is greater than the holding force of the holding means.
When the holding force of the holding means is overcome, the motion of the heddle is brought about for the most part by the spring force of the leaf spring 14 , and the linear motor 12 moves along with this motion without significantly contributing to it. When the other end position is reached, the leaf spring 14 remains deflected, since the holding force of the holding means in this position is greater than the restoring force of the leaf spring 14 , and the linear motor 12 does not assist the latter.
LIST OF DESIGNATIONS
2 heddle apparatus
2 1 - 2 6 group of heddle apparatuses
4 heddle frame
6 heddle support
8 heddle connector
10 support frame
12 linear motor
14 leaf spring
16 leaf spring
18 shedding block
20 spring holder
22 shedding block
24 upper stop magnet
26 lower stop magnet
28 block part
30 upper magnetic counter-holder
32 lower magnetic counter-holder
34 flat coil
36 upper coil magnet
38 lower coil magnet
40 heddles
42 weaving reed
44 reed support
46 electrical conductors
48 connection plate
50 warp threads
100 spring force diagram
102 magnetic force diagram
104 coil force diagram
106 warp thread force diagram
130 upper holding element
132 lower holding element
M center line
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In order to make a small space requirement, a low energy requirement and therefore an increased weaving frequency possible in a shedding apparatus, a spring drive is proposed which is connected to magnetically acting holding means. The holding means are capable of holding the heddle frame in an upper shed position and in a lower shed position counter to the spring force. Furthermore, the heddle frame is connected to a linear motor. A heddle movement can be initiated by said linear motor. According to the invention, the spring drive is configured as a tension/compression spring which is designed in such a way that, during operation of the heddle frame at the resonant frequency of the spring drive the greater part of the kinetic energy can be obtained from the spring drive.
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INCORPORATION BY REFERENCE
[0001] This application claims the benefit of Chinese Patent Application No. 201320625763.6, filed Oct. 11, 2013, which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention generally relates to lighting technology, and, more particularly, a work light.
BACKGROUND OF THE INVENTION
[0003] Work lights are widely used in automotive repair shops and other repair settings and construction settings. Such work lights are often in a form that can alternatively be handheld or hung from a suitable elevated object such as a raised automobile hood.
[0004] Currently, on the market, most of the work lights require a fixed running power source to power the light bulbs. In the situations such as underwater adventure, camping, road-side car fixing, outdoor living, etc., where a fixed running power source is not available, a self powered and portable work light is desired.
[0005] Even in the traditional settings where work lights have been used, the power cord is a drawback users want to eliminate because it clutters the already cluttered workspace, knocking down and tangling with tools and/or objects in the workspace. Furthermore, running power cord is a hazard if it tangles with and is damaged by a tool. Clearly, a work light without a power cord is desirable.
[0006] Furthermore, unlike incandescent and fluorescent work lights which often comprise at least one glass light bulb, LED work lights are better able to survive falls than are work lights that have glass bulbs. Furthermore, LEDs do not generally operate with parts hot enough to ignite flammable materials, so even falls that do result in breakage are less likely to cause fires than are similar falls of work lights that have glass bulbs.
[0007] The prior art has LED work lights, but because of the running power source requirement, their uses are limited to certain settings, i.e., automobile repair shop, indoor work, etc. Thus, they mostly produce one solid white or yellowish light. Therefore, they are inadequate to use in other settings, such as camping, outdoor games, road-side emergency, outdoor emergency, etc., where a multiple color or blinkable light source is desired to be used as a signal.
[0008] Moreover, in a submerging setting like an underwater adventure, a submerging electrical current is a hazard and a tangled power cord is a serious problem. Thus, most applications of current work lights are on land. Clearly, a cordless, self powered, and portable work light is desirable in these settings.
OBJECT OF THE INVENTION
[0009] Accordingly, one objective of this invention is to provide a self powered work light.
[0010] Another objective of this invention is to provide a convenient portable work light.
[0011] Yet another objective of this invention is to provide a versatile work light.
[0012] Yet another objective of this invention is to provide a multiple color work light.
[0013] Yet another objective of this invention is to provide a blinkable work light.
[0014] Yet another objective of this invention is to provide a waterproof work light.
SUMMARY OF THE INVENTION
[0015] In one aspect of the invention, an utility working light apparatus is disclosed comprising a switch cover unit, a handle end unit, a tube apparatus enclosed between the switch cover unit and the handle end unit, the switch cover unit comprising a first magnetic apparatus;
[0016] the tube apparatus further comprising a PCB LED board; the handle end unit further comprising at least one sealing apparatus and a threaded end cap. In one embodiment, the tube apparatus is a polycarbonate tube. In one embodiment, the polycarbonate tube is comprised of at least two difference shades. In one embodiment, the sealing apparatus is an O-ring. In one embodiment, the PCB LED board is capable of generating light brightness in multiple modes. In one embodiment, the PCB LED board is capable of generating light in terms of color in multiple modes. In one embodiment, the first magnetic apparatus is a magnetic ring. In one embodiment, the switch cover unit is further comprising of a push button switch. In one embodiment, the handle end unit is further comprising of a second magnetic apparatus. In one embodiment, the second magnetic apparatus is a magnetic block. In one embodiment, the handle end unit further comprising a USB charging connector. In one embodiment, the tube apparatus is further comprising of a battery charge indicator.
BRIEF DESCRIPTIONS OF THE DRAWINGS
[0017] FIG. 1 is a schematic exploded view of an exemplary work light.
[0018] FIG. 2 is a perspective exploded view of an exemplary work light.
[0019] FIG. 3 is a side view of an exemplary switch cover.
DETAILED DESCRIPTION OF THE INVENTION
[0020] The following detailed description of the preferred embodiments presents a description of certain specific embodiments as examples of a plurality of ways to practice this invention. As such, one may practice the present invention in a multitude of different embodiments as defined and covered by the claims.
[0021] In some instances, certain features are described in less or more detail. The level of detail associated with each of the elements or features should not be construed to qualify the novelty or importance of one feature over the others.
[0022] Certain marks referenced herein may be trademarks, whose use is to provide an enabling disclosure by way of example and shall not be construed to exclusively limit the scope of the disclosed subject matter to material associated with such marks.
[0023] References in this specification to “an embodiment”, “one embodiment”, “one or more embodiments” or the like, simply mean that the particular element, feature, structure or characteristic being described is in at least one embodiment of the disclosed subject matter. The occurrences of such phrases do not necessarily refer to the same embodiment, nor do they necessarily to mutually exclusive embodiments with respect to the discussed features or elements.
[0024] Various exemplary embodiments disclosed herein are directed to a work light that is convenient, versatile, and waterproof.
[0025] Referring to FIG. 1 , in one embodiment, a work light comprises a switch cover 1 , which prevents the switch from flipping in the event of a drop. The work light further comprises a strong magnetic ring 3 and a powerful magnet 2 , which are positioned inside the female threaded cavity of the switch cover 1 . The strong magnets can attach the work light to metal objects, fixtures or auto frames. The work light further comprises a Printed Circuit Board (PCB) light board 4 , which is positioned inside a color tube 5 , and their one ends are attached to the switch cover 1 such that the attachment is waterproof, using attaching methods appreciated by a person ordinarily skilled in the art. At the other ends of the PCB board 4 and color tube 5 are attached a powerful magnet 6 , a strong magnetic block 7 , and a handle end 8 . Similarly, the attachment is made waterproof, and the magnets are positioned inside the cavity of the handle end 8 . The strong magnets can also be used to attach the work light to metal objects, fixtures or auto frames. The other end of the handle end 8 is male threaded to receive an O-ring seal 9 , and a female threaded end cap 10 . The O-ring 9 and end cap 10 seal the work light from water and the elements. The cavity of the handle end 8 houses a rechargeable lithium battery.
[0026] Referring to FIG. 2 , in one embodiment, a work light comprises a switch cover 1 , a color tube 5 , a handle end 8 , and a battery discharge indicator 11 , that has a red, yellow, and green color indicators for a low, half power, and fully charged battery, respectively. The work light further comprises a USB charging jack 12 positioned in the cavity of the handle end 8 and facing the end cap 10 . The USB charging jack 12 is used to charge the rechargeable lithium battery also positioned in the cavity of the handle end 8 .
[0027] Referring to FIG. 3 , in one embodiment, the work light comprises a switch cover 1 and a push-button switch 13 , which is positioned inside the cavity of the switch cover. It is appreciated that the push-button switch 13 is made waterproof and seals the work light from water and the elements. In one embodiment, the push-button switch 13 can be long pressed to toggle the work light on and off.
[0028] In one embodiment, the PCB LED board 4 has eight light modes, where the first push-button switch 13 click produces a white light, the second click a red light, the third click a green light, the fourth click a blue light, the fifth click a red blinking light, the sixth click a red burst flash light, the seventh click a yellow blinking light, and the eighth click a yellow burst flash light.
[0029] In one embodiment, the PCB LED board 4 has five light modes, where the first click of the push-button switch 13 produces the strongest light in terms of brightness, the second click produces the normal light in terms of brightness, the third click generates mild light to save energy, a fourth click causes blinking light and the fifth click causes excess bright blinking light.
[0030] In one embodiment, the work light can be 6, 8, 10, 12, 15, 18, 24 inches, or longer. It is appreciated that the longer or larger the work light is, the more battery capacity may be required.
[0031] Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement that is calculated or designed to achieve the same purposes may be substituted for the specific embodiments shown. Many adaptations of the disclosure will be apparent to those of ordinary skill in the art. Accordingly, this application is intended to cover any adaptations or variations of the disclosure.
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An utility working light apparatus comprising a switch cover unit, a handle end unit, a tube apparatus enclosed between the switch cover unit and the handle end unit, the switch cover unit comprising a first magnetic apparatus; the tube apparatus further comprising a PCB LED board; the handle end unit further comprising at least one sealing apparatus and a threaded end cap.
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This is a divisional application of U.S. Ser. No. 07/585,758 filed Sep. 20, 1990, now U.S. Pat. No. 5,045,550.
BACKGROUND OF THE INVENTION
The present invention relates to novel substituted tetrahydropyridines and derivatives thereof useful as pharmaceutical agents, to methods for their production, to pharmaceutical compositions which include these compounds and a pharmaceutically acceptable carrier, and to pharmaceutical methods of treatment. The novel compounds of the present invention are central nervous system agents. More particularly, the novel compounds of the present invention are dopaminergic agents.
A series of pyridine derivatives of the formula ##STR1## wherein R 1 and R 2 are independently each phenyl or 2- or 3-thienyl radicals which are unsubstituted or monosubstituted or disubstituted by alkyl, alkoxy, F, Cl, Br, OH, and/or CF 3 and n is 1, 2, or 3, and the alkyl and alkoxy groups each have 1-4 C atoms and salts thereof having suppressant actions on the central nervous system is disclosed in U.S. Pat. No. 4,665,187.
However, the compounds disclosed in the aforementioned references do not disclose or suggest the combination of structural variations of the compounds of the present invention described hereinafter.
SUMMARY OF THE INVENTION
Accordingly, the present invention is a compound of Formula I ##STR2## wherein R is ##STR3## X is ##STR4## or --CH 2 --; n is an of 2 to 4;
R 1 is aryl, 2- or 3-1H-indolyl, or 2- or 3-1H-indolyl substituted by lower alkyl, lower alkoxy, or halogen, 2-, 3-, or 4-pyridinyl, or 2-, 3-, or 4-pyridinyl substituted by lower alkyl, lower alkoxy, or halogen, 2-, 4-, or 5-pyrimidinyl, or 2-, 4-, or 5-pyrimidinyl substituted by lower alkyl, lower alkoxy, or halogen, 2-pyrazinyl or 2-pyrazinyl substituted by lower alkyl, lower alkoxy, or halogen, 2- or 3-thienyl, or 2- or 3-thienyl substituted by lower alkyl or halogen, 2- or 3-furanyl, or 2- or 3-furanyl substituted by lower alkyl or halogen, 2-, 4-, or 5-thiazolyl, or 2-, 4-, or 5-thiazolyl substituted by lower alkyl or halogen; or a pharmaceutically acceptable acid addition salt thereof.
As dopaminergic agents, the compounds of Formula I are useful as antipsychotic agents for treating psychoses such as schizophrenia. They are also useful as antihypertensives and for the treatment of disorders which respond to dopaminergic activation. Thus, other embodiments of the present invention include the treatment, by a compound of Formula I, of hyperprolactinaemia-related conditions, such as galactorrhea, amenorrhea, menstrual disorders and sexual dysfunction, and several central nervous system disorders such as Parkinson's disease, Huntington's chorea, and depression.
A still further embodiment of the present invention is a pharmaceutical composition for administering an effective amount of a compound of Formula I in unit dosage form in the treatment methods mentioned above.
Finally, the present invention is directed to methods for production of a compound of Formula I.
DETAILED DESCRIPTION OF THE INVENTION
In the compounds of Formula I, the term "lower alkyl" means a straight or branched hydrocarbon radical having from one to six carbon atoms and includes, for example, methyl, ethyl, n-propyl, isopropyl, n-butyl, sec-butyl, isobutyl, tert-butyl, n-pentyl, n-hexyl, and the like.
The term "aryl" means an aromatic radical which is a phenyl group or phenyl group substituted by one to four substituents selected from lower alkyl, lower alkoxy, lower thioalkoxy, halogen or trifluoromethyl such as, for example, benzyl, phenethyl, and the like.
"Lower alkoxy" and "thioalkoxy" are O-alkyl or S-alkyl of from one to six carbon atoms as defined above for "lower alkyl."
"Halogen" is fluorine, chlorine, bromine, or iodine.
"Alkali metal" is a metal in Group IA of the periodic table and includes, for example, lithium, sodium, potassium, and the like.
"Alkaline-earth metal" is a metal in Group IIA of the periodic table and includes, for example, calcium, barium, strontium, magnesium, and the like.
"Noble metal" is platinum, palladium, rhodium, ruthenium, and the like.
Pharmaceutically acceptable acid addition salts of the compounds of Formula I include salts derived from nontoxic inorganic acids, such as hydrochloric, nitric, phosphoric, sulfuric, hydrobromic, hydriodic, phosphorous, and the like, as well as the salts derived from nontoxic organic acids, such as aliphatic mono- and dicarboxylic acids, phenyl-substituted alkanoic acids, hydroxy alkanoic acids, alkanedioic acids, aromatic acids, aliphatic and aromatic sulfonic acids, etc. Such salts thus include sulfate, pyrosulfate, bisulfate, sulfite, bisulfite, nitrate, phosphate, monohydrogenphosphate, dihydrogenphosphate, metaphosphate, pyrophosphate, chloride, bromide, iodide, acetate, propionate, caprylate, isobutyrate, oxalate, malonate, succinate, suberate, sebacate, fumarate, maleate, mandelate, benzoate, chlorobenzoate, methylbenzoate, dinitrobenzoate, phthalate, benzenesulfonate, toluenesulfonate, phenylacetate, citrate, lactate, maleate, tartrate, methanesulfonate, and the like. Also contemplated are salts of amino acids such as arginate and the like and gluconate, galacturonate (see, for example, Berge, S. M., et al, "Pharmaceutical Salts," Journal of Pharmaceutical Science, Vol. 66, pages 1-19 (1977)).
The acid addition salts of said basic compounds are prepared by contacting the free base form with a sufficient amount of the desired acid to produce the salt in the conventional manner. The free base form may be regenerated by contacting the salt form with a base and isolating the free base in the conventional manner. The free base forms differ from their respective salt forms somewhat in certain physical properties such as solubility in polar solvents, but otherwise the salts are equivalent to their respective free base for purposes of the present invention.
Certain of the compounds of the present invention can exist in unsolvated forms as well as solvated forms, including hydrated forms. In general, the solvated forms, including hydrated forms, are equivalent to unsolvated forms and are intended to be encompassed within the scope of the present invention.
A preferred compound of Formula I is one wherein R 1 is aryl, 2- or 3-1H-indolyl, or 2- or 3-1H-indolyl substituted by lower alkyl, lower alkoxy, or halogen, 2-, 3-, or 4-pyridinyl or 2-, 3-, or 4-pyridinyl substituted by lower alkyl, lower alkoxy, or halogen, 2-, 4-, or 5-pyrimidinyl or 2-, 4-, or 5-pyrimidinyl substituted by lower alkyl, lower alkoxy, or halogen, 2- or 3-thienyl or 2- or 3-thienyl substituted by lower alkyl or halogen.
Another preferred embodiment is a compound of Formula I wherein R 1 is aryl, 2- or 3-1H-indolyl, 2-, 3-, or 4-pyridinyl, 2-, 4-, or 5-pyrimidinyl, or 2- or 3-thienyl.
Particularly valuable are:
4-(3,6-Dihydro-4-phenyl-1(2H)-pyridinyl)-1-(3-pyridinyl)-1-butanone;
3-[4-(3,6-Dihydro-4-phenyl-1(2H)-pyridinyl)-butyl]pyridine;
3-[4-[3,6-Dihydro-4-(2-thienyl)-1(2H)-pyridinyl]-butyl]pyridine;
4-(3,6-Dihydro-4-phenyl-1(2H)-pyridinyl)-1-(4-pyridinyl)-1-butanone;
4-[4-(3,6-Dihydro-4-phenyl-1(2H)-pyridinyl)-butyl]pyridine;
2-[1,2,3,6-Tetrahydro-1-[4-(4-pyridinyl)butyl]-4-pyridinyl]pyridine;
3-[1,2,3,6-Tetrahydro-1-[4-(4-pyridinyl)butyl]-4-pyridinyl]-1H-indole;
4-[4-[3,6-Dihydro-4-(2-thienyl)-1(2H)-pyridinyl]-butyl]pyridine;
4-[3-(3,6-Dihydro-4-phenyl-1(2H)-pyridinyl)-propyl]pyridine;
4-[5-(3,6-Dihydro-4-phenyl-1(2H)-pyridinyl)-pentyl]pyridine;
3-[4-(3,6-Dihydro-4-phenyl-1(2H)-pyridinyl)-butyl]quinoline;
3-[4-[3,6-Dihydro-4-(2-pyridinyl)-1(2H)-pyridinyl]butyl]quinoline;
2-[1,2,3,6-Tetrahydro-1-[4-(3-pyridinyl)butyl]-4-pyridinyl]pyridine;
4-(3,6-Dihydro-4-phenyl-1(2H)-pyridinyl)-1-(3-quinolinyl)-1-butanone;
3-[3-[3,6-Dihydro-4-(2-thienyl)-1(2H)-pyridinyl]propyl]quinoline;
3-[3-(3,6-Dihydro-4-phenyl-1(2H)-pyridinyl)-propyl]quinoline;
3-[5-[3,6-Dihydro-4-(2-thienyl)-1(2H)-pyridinyl]-butyl]quinoline;
3-[5-(3,6-Dihydro-4-phenyl-1(2H)-pyridinyl)-pentyl]quinoline; and
3-[5-(3,6-Dihydro-4-(2-thienyl)-1(2H)-pyridinyl]-pentyl]quinoline;
or a pharmaceutically acceptable acid addition salt thereof.
The compounds of Formula I are valuable dopaminergic agents. The tests employed indicate that compounds of Formula I possess dopaminergic activity. Thus, the compounds of Formula I were tested for their ability to inhibit locomotor activity in mice according to the assay described by J. R. McLean, et al, Pharmacology, Biochemistry and Behavior, Volume 8, pages 97-99 (1978); for their ability to inhibit [ 3 H]-spiroperidol binding in a receptor assay described by D. Grigoriadis and P. Seeman, Journal of Neurochemistry, Volume 44, pages 1925-1935 (1985); and for their ability to inhibit dopamine synthesis in rats according to the protocol described by J. R. Walters and R. H. Roth, Naunyn-Schmiedeberg's Archives of Pharmacology, Volume 296, pages 5-14 (1976). The above test methods are incorporated herein by reference. The data in the table show the dopaminergic activity of representative compounds of Formula I.
TABLE 1__________________________________________________________________________Biological Activity of Compounds of Formula I % Reversal Inhibition of Brain of Locomotor Dopamine Inhibition of Activity Synthesis [.sup.3 H]SpiroperidolExample in Mice in Rats at BindingNumberCompound ED.sub.50, mg/kg, IP 10 mg/kg, IP IC.sub.50, μM__________________________________________________________________________9 4-(3,6-Dihydro-4-phenyl-1(2 .sub.-- H)- 1.1 50 --pyridinyl)-1-(3-pyridinyl)-1-butanone12 3-[4-(3,6-Dihydro-4-phenyl- 0.28 80 0.171(2 .sub.-- H)-pyridinyl)butyl]pyridine8 3-[4-[3,6-Dihydro-4-(2-thienyl)- 0.66 71 1.291(2 .sub.-- H)-pyridinyl]butyl]pyridine10 4-(3,6-Dihydro-4-phenyl-1(2 .sub.-- H)- 1.0 57 0.408pyridinyl)-1-(4-pyridinyl)-1-butanone1 4-[4-(3,6-Dihydro-4-phenyl-1(2H)- 0.6 87 0.096pyridinyl)butyl]pyridine2 2-[1,2,3,6-Tetrahydro-1-[4-(4- 0.7 88 0.448pyridinyl)butyl]-4-pyridinyl]-pyridine3 3-[1,2,3,6-Tetrahydro-1-[4- 5.0 -- 0.398(4-pyridinyl)butyl]pyridinyl]]-1 .sub.-- H-indole4 4-[4-[3,6-Dihydro-4-(2-thienyl)- 1.2 -- 0.691(2H)-pyridinyl]butyl]pyridine5 4-[3-(3,6-Dihydro-4-phenyl-1(2H)- 0.63 61 --pyridinyl)propyl] pyridine7 4-[5-(3,6-Dihydro-4-phenyl-1(2H)- 0.90 -- --pyridinyl)pentyl]pyridine13 3-[4-(3,6-Dihydro-4-phenyl-1-(2 .sub.-- H)- 0.37 100 0.046pyridinyl)butyl]quinoline15 3-[4-[3,6-Dihydro-4-(2-pyridinyl)]- 0.14 -- --1-(2 .sub.-- H)-pyridinyl]butyl]quinoline14 3-[5-[3,6-Dihydro-4-(2-thienyl)]-1- 1.50 -- --(2 .sub.-- H)-pyridinyl]butyl]quinoline__________________________________________________________________________
A compound of Formula Ia ##STR5## wherein R is ##STR6## n is an integer of 2 to 4;
R 1 is aryl, 2- or 3-1H-indolyl, or 2- or 3-1H-indolyl substituted by lower alkyl, lower alkoxy, or halogen, 2-, 3-, or 4-pyridinyl, or 2-, 3-, or 4-pyridinyl substituted by lower alkyl, lower alkoxy, or halogen, 2-, 4-, or 5-pyrimidinyl, or 2-, 4-, or 5-pyrimidinyl substituted by lower alkyl, lower alkoxy, or halogen, 2-pyrazinyl or 2-pyrazinyl substituted by lower alkyl, lower alkoxy, or halogen, 2- or 3-thienyl, or 2- or 3-thienyl substituted by lower alkyl or halogen, 2- or 3-furanyl, or 2- or 3-furanyl substituted by lower alkyl or halogen, 2-, 4-, or 5-thiazolyl, or 2-, 4-, or 5-thiazolyl substituted by lower alkyl or halogen; or a pharmaceutically acceptable acid addition salt thereof may be prepared by reacting a compound of Formula Ib ##STR7## wherein R, R 1 , and n are as defined above with a reducing agent such as, for example, hydrazine, in the presence of an alkaline catalyst such as sodium hydroxide, potassium hydroxide, sodium methoxide, sodium ethoxide and the like, and a solvent such as, for example, ethylene glycol and the like, or amalgamated zinc and an acid such as, for example, concentrated hydrochloric acid and the like, optionally in the presence of a solvent such as, for example, ethanol, acetic acid, dioxane, toluene and the like, or treating a compound of Formula Ib with hydrogen in the presence of a catalyst such as a noble metal, for example, palladium on charcoal in the presence of a solvent such as, for example, ethanol and the like to give a compound of Formula Ia. Preferably, the reaction is carried out with hydrazine in the presence of potassium hydroxide and ethylene glycol.
Alternatively, a compound of Formula Ia may be prepared from a compound of Formula II
R--CH.sub.2 --(CH.sub.2).sub.n --L (II)
wherein L is a halogen, or a leaving group such as, for example, methanesulfonyloxy, toluenesulfonyloxy and the like, and R and n are as defined above, and a compound of Formula III ##STR8## wherein R 1 is as defined above in the presence of a base such as, for example, an alkali metal or alkaline earth metal hydroxide, carbonate or bicarbonate, for example, sodium hydroxide, sodium carbonate, sodium bicarbonate, potassium hydroxide, potassium carbonate, potassium bicarbonate and the like in the presence of a solvent such as, for example, acetonitrile and the like to give a compound of Formula Ia. Preferably, the reaction is carried out in the presence of potassium bicarbonate and acetonitrile.
A compound of Formula Ib is prepared from a compound of Formula IV ##STR9## wherein R, N, and L are as defined above and a compound of Formula III using the methodology used to prepare a compound of Formula Ia from a compound of Formula II and a compound of Formula III.
Compounds of Formula II, Formula III, and Formula IV are either known or capable of being prepared by methods known in the art.
The compounds of the present invention can be prepared and administered in a wide variety of oral and parenteral dosage forms. It will be obvious to those skilled in the art that the following dosage forms may comprise as the active component, either a compound of Formula I or a corresponding pharmaceutically acceptable salt of a compound of Formula I.
For preparing pharmaceutical compositions from the compounds of the present invention, pharmaceutically acceptable carriers can be either solid or liquid. Solid form preparations include powders, tablets, pills, capsules, cachets, suppositories, and dispersible granules. A solid carrier can be one or more substances which may also act as diluents, flavoring agents, solubilizers, lubricants, suspending agents, binders, preservatives, tablet disintegrating agents, or an encapsulating material.
In powders, the carrier is a finely divided solid which is in a mixture with the finely divided active component.
In tablets, the active component is mixed with the carrier having the necessary binding properties in suitable proportions and compacted in the shape and size desired.
The powders and tablets preferably contain from five or ten to about seventy percent of the active compound. Suitable carriers are magnesium carbonate, magnesium stearate, talc, sugar, lactose, pectin, dextrin, starch, gelatin, tragacanth, methylcellulose, sodium carboxymethylcellulose, a low melting wax, cocoa butter, and the like. The term "preparation" is intended to include the formulation of the active compound with encapsulating material as a carrier providing a capsule in which the active component, with or without other carriers, is surrounded by a carrier, which is thus in association with it. Similarly, cachets and lozenges are included. Tablets, powders, capsules, pills, cachets, and lozenges can be used as solid dosage forms suitable for oral administration.
For preparing suppositories, a low melting wax, such as a mixture of fatty acid glycerides or cocoa butter, is first melted and the active component is dispersed homogeneously therein, as by stirring. The molten homogenous mixture is then poured into convenient sized molds, allowed to cool, and thereby to solidify.
Liquid form preparations include solutions, suspensions, and emulsions, for example, water or water propylene glycol solutions. For parenteral injection liquid preparations can be formulated in solution in aqueous polyethylene glycol solution.
Aqueous solutions suitable for oral use can be prepared by dissolving the active component in water and adding suitable colorants, flavors, stabilizing and thickening agents as desired.
Aqueous suspensions suitable for oral use can be made by dispersing the finely divided active component in water with viscous material, such as natural or synthetic gums, resins, methylcellulose, sodium carboxymethylcellulose, and other well-known suspending agents.
Also included are solid form preparations which are intended to be converted, shortly before use, to liquid form preparations for oral administration. Such liquid forms include solutions, suspensions, and emulsions. These preparations may contain, in addition to the active component, colorants, flavors, stabilizers, buffers, artificial and natural sweeteners, dispersants, thickeners, solubilizing agents, and the like.
The pharmaceutical preparation is preferably in unit dosage form. In such form the preparation is subdivided into unit doses containing appropriate quantities of the active component. The unit dosage form can be a packaged preparation, the package containing discrete quantities of preparation, such as packeted tablets, capsules, and powders in vials or ampoules. Also, the unit dosage form can be a capsule, tablet, cachet, or lozenge itself, or it can be the appropriate number of any of these in packaged form.
The quantity of active component in a unit dose preparation may be varied or adjusted from 1 mg to 1000 mg preferably 10 mg to 100 mg according to the particular application and the potency of the active component. The composition can, if desired, also contain other compatible therapeutic agents.
In therapeutic use as antipsychotic agents, the compounds utilized in the pharmaceutical method of this invention are administered at the initial dosage of about 1 mg to about 50 mg per kilogram daily. A daily dose range of about 5 mg to about 25 mg per kilogram is preferred. The dosages, however, may be varied depending upon the requirements of the patient, the severity of the condition being treated, and the compound being employed. Determination of the proper dosage for a particular situation is within the skill of the art. Generally, treatment is initiated with smaller dosages which are less than the optimum dose of the compound. Thereafter, the dosage is increased by small increments until the optimum effect under the circumstances is reached. For convenience, the total daily dosage may be divided and administered in portions during the day, if desired.
The following nonlimiting examples illustrate the inventors' preferred methods for preparing the compounds of the invention.
EXAMPLE 1
4-[4-(3,6-Dihydro-4-phenyl-1(2H)-pyridinyl)butyl]-pyridine
A mixture of 4-(4-pyridinyl)-1-butylchloride (Example A) (0.76 g, 4.47 mmol), 1,2,3,6-tetrahydro-4-phenylpyridine (0.796 g, 5.0 mmol), and potassium bicarbonate (1.0 g, 10 mmol) in 5 mL of acetonitrile are heated to reflux for 8 hours. The reaction is cooled to room temperature and the acetonitrile removed in vacuo. The residue is partitioned between 50 mL of water and 50 mL of chloroform. The aqueous layer is extracted again with 50 mL of chloroform and the combined organic extracts are dried over sodium sulfate and the solvent removed in vacuo. The resulting residue is chromatographed on silica gel (2% to 3% methanol, 0.1% ammonia, chloroform) to obtain 1.10 g of 4-[4-(3,6-dihydro-4-phenyl-1(2H)-pyridinyl)-butyl]pyridine as a white solid; mp 89°-90° C.
In a process analogous to Example 1 using appropriate starting materials, the corresponding compounds of Formula I (Examples 2 to 8) are prepared as follows:
EXAMPLE 2
2-[1,2,3,6-Tetrahydro-1-[4-(4-pyridinyl)butyl]-4-pyridinyl]pyridine; mp 98°-99° C.
EXAMPLE 3
3-[1,2,3,6-Tetrahydro-1-[4-(4-pyridinyl)butyl]-4-pyridinyl]]-1H-indole; mp 177°-178° C.
EXAMPLE 4
4-[4-[3,6-Dihydro-4-(2-thienyl)-1(2H)-pyridinyl]-butyl]pyridine; mp 86-87° C.
EXAMPLE 5
4-[3-(3,6-Dihydro-4-phenyl-1(2H)-pyridinyl)propyl]-pyridine; mp 166°-168° C.
EXAMPLE 6
2-[1,2,3,6-Tetrahydro-1-[4-(3-pyridinyl)butyl]-4-pyridinyl]pyridine.
EXAMPLE 7
4-[5-(3,6-Dihydro-4-phenyl-1(2H)-pyridinyl)pentyl]-pyridine; mp 125°-126° C.
EXAMPLE 8
4-[4-[3,6-Dihydro-4-(2-thienyl)-1(2H)-pyridinyl]-butyl]pyridine; mp 44°-46° C.
EXAMPLE 9
4-(3,6-Dihydro-4-phenyl-1(2H)-pyridinyl)-1-(3-pyridinyl)-1-butanone
A solution of 4-chloro-3-(3-pyridinyl)-1-butanone (Example D) (17.8 g, 0.097 mol), 4-phenyl-1,2,3,6-tetrahydropyridine (44.7 g, 0.281 mol), and potassium iodide (0.8 g, 0.005 mol) are heated on a steam bath for 15 minutes. The residue is taken up in chloroform (60 mL) and the precipitate is filtered. The filtrate is evaporated in vacuo and purified by column chromatography (silica gel, 2% methanol/dichloromethane). The major product is crystallized from diethyl ether to give 4.5 g of 4-(3,6-dihydro-4-phenyl-1(2H)-pyridinyl)-1-(3-pyridinyl)-1-butanone as a solid; mp 64°-66° C.
In a process analogous to Example 9 using appropriate starting materials the corresponding compounds of Formula I (Examples 10 to 12) are prepared as follows:
EXAMPLE 10
4-(3,6-Dihydro-4-phenyl-1(2H)-pyridinyl)-1-(4-pyridinyl)-1-butanone; mp 97°-98° C.
EXAMPLE 11
4-(3,6-Dihydro-4-phenyl-1(2H)-pyridinyl)-1-(3-quinolinyl)-1-butanone; mp 106°-107° C.
EXAMPLE 12
3-[4-(3,6-Dihydro-4-phenyl-1(2H)-pyridinyl)butyl]-pyridine; mp 45°-46° C.
EXAMPLE 13
3-[4-(3,6-Dihydro-4-phenyl-1(2H)-pyridinyl)butyl]-quinoline
A solution of 4-(3-quinolinyl)butan-1-ol (Example E) (2.0 g, 0.01 mol), N,N-diisopropylethylamine (3.5 mL, 0.02 mol) and a catalytic amount of 4-dimethylaminopyridine is cooled to 0° C. and methanesulfonyl chloride (0.8 mL, 0.0105 mol) is added dropwise. The solution is stirred at 0° C. for 18 hours, and concentrated under reduced pressure. The residue is taken up in dimethylformamide (20 mL), and to this solution is added 4-phenyl-1,2,3,6-tetrahydropyridine (2.41 g, 0.015 mol) and sodium bicarbonate (3.4 g, 0.04 mol). The mixture is heated at 40° C. for 5 hours and the solvent removed under reduced pressure. The residue is partitioned between 50 mL of ethyl acetate and 50 mL of water. The aqueous layer is extracted with 50 mL of ethyl acetate and the organic extracts are dried (sodium sulfate) and the solvent removed in vacuo. The residue is chromatographed (silica gel, 2% methanol/98% dichloromethane) to give 2.15 g of the title compound; mp 92.8°-93.9° C.
In a process analogous to Example 13 using appropriate starting materials the corresponding compounds of Formula I (Examples 14 to 19) are prepared as follows:
EXAMPLE 14
3-[5-[3,6-Dihydro-4-(2-thienyl-1(2H)-pyridinyl]-butyl]quinoline; mp 73.8°-74.8° C.
EXAMPLE 15
3-[4-[3,6-Dihydro-4-(2-pyridinyl)-1(2H)-pyridinyl]-butyl]quinoline; mp 81.2°-81.6° C.
EXAMPLE 16
3-[3-[3,6-Dihydro-4-(2-thienyl)-1(2H) pyridinyl]-propyl]quinoline.
EXAMPLE 17
3-[3-(3,6-Dihydro-4-phenyl-1(2H)-pyridinyl)propyl]-quinoline dihydrochloride salt; mp 166°-167° C.
EXAMPLE 18
3-[5-[3,6-Dihydro 4-(2-thienyl)-1(2H)-pyridinyl]- pentyl]quinoline.
EXAMPLE 19
3-[5-(3,6-Dihydro-4-phenyl-1(2H)-pyridinyl)pentyl]-quinoline dihydrochloride salt; mp 162°-163° C.
PREPARATION OF STARTING MATERIALS
EXAMPLE A
4-(4-Pyridinyl)-1-butylchloride
A solution of 4-(4-pyridinyl)-1-butanol (Mayer J. M. and Testa, B., Helv. Chim. Acta 65, pages 1868-1884 (1982)) (4.20 g, 27.7 mmol) in 30 mL of chloroform is cooled to 0° C. and treated with thionyl chloride (6.60 g, 55.54 mmol) in 30 mL of chloroform. The reaction is allowed to warm to room temperature over 15 hours. The volatiles are removed in vacuo. The residue is cooled to 0° C. and treated with 50 mL of cold 10% sodium hydroxide solution and the mixture is extracted with three 100-mL portions of chloroform. The combined organic extracts are dried over sodium sulfate and the solvents are removed under reduced pressure to give 4.25 g of 4-(4-pyridinyl)-1-butylchloride as a brown oil.
In a process analogous to Example A using appropriate starting materials the corresponding compound was prepared as follows:
EXAMPLE B
3-(4-Pyridinyl)-1-propylchloride (Mayer, J. M. and Testa, B., Helv. Chim. Acta, pages 1868-1884 (1982)).
EXAMPLE C
5-(4-Pyridinyl)-pentylchloride
Step A: Preparation of 4-(Chlorobutoxy)-3,4,5,6-2H-tetrahydropyran
A solution of 4-chlorobutanol (23.2 g, 0.2140 mol) and 2 drops of concentrated hydrochloric acid at 0° C. is treated with 3,4-dihydro-2H-pyran (15 g, 0.1783 mol). The reaction is allowed to warm to room temperature over 3 hours. The reaction mixture is purified by distillation (130° C., 20 mm) to give 18.07 g of 2-(4-chlorobutoxy)-3,4,5,6-2H-tetrahydropyran as a colorless oil.
Step B: Preparation of 5-(4-Pyridinyl)-1-pentanol
Phenyl lithium (1.8 M cyclohexane diethyl ether, 27.6 mL, 0.0497 mol) is slowly added to a stirring solution of 4-picoline (4.6 g, 0.0497 mol) in 50 mL of tetrahydrofuran under nitrogen. The solution is stirred for 20 minutes at room temperature and then cooled to 0° C. 2-(4-Chlorobutoxy)-3,4,5,6-2H-tetrahydropyran (6.4 g, 0.0332 mol) is slowly added to the reaction mixture and the mixture is stirred for 30 minutes at 0° C. The reaction mixture is refluxed for 12 hours, cooled, and 100 mL of 10% hydrochloric acid solution is added. The reaction mixture is stirred for another 12 hours and then made basic with a saturated solution of sodium bicarbonate and extracted with chloroform. The organic phase is dried (sodium sulfate) and evaporated in vacuo. The resulting residue is chromatographed on silica gel (ethyl acetate) to give 1.25 g of 5-(4-pyridinyl)-1 pentanol as a brown oil.
Step C: Preparation of 5-(4-pyridinyl)-1-pentylchloride
A solution of 5-(4-pyridinyl)-1-pentanol (3.71 g, 0.0225 mol) in 50 mL of chloroform is treated with thionyl chloride (5.4 g, 0.0449 mol) in 25 mL of chloroform. The resulting solution is neutralized with a saturated solution of sodium bicarbonate and extracted with chloroform. The organic phase is dried (sodium sulfate) and evaporated in vacuo to give 3.86 g of 5-(4-pyridinyl)-1-pentylchloride as a brown oil.
EXAMPLE D
4-Chloro-1-(3-pyridinyl)-1-butanone (Sato, M., et al, Chem. Pharm. Bull., 26, 3296 (1978)).
A solution of methyl nicotinate (59 g, 0.43 mol), 4-hydroxybutyric acid lactone (51.8 g, 0.602 mol), and sodium methoxide (70 g, 1.29 mol) in dioxane (500 mL) is refluxed for 1 hour and then cooled. Concentrated hydrochloric acid (650 mL) is added, and the reaction mixture is refluxed for 12 hours. The resulting solution is neutralized with solid sodium bicarbonate and extracted with chloroform. The organic phase is dried (sodium sulfate), and the solvent evaporated in vacuo. The residue is taken up in 2-propanol (50 mL) and treated with a saturated solution of hydrogen chloride in 2-propanol. The hydrochloride salt of 4-chloro-1-(3-pyridinyl)-1-butanone is obtained as a white solid (30 g); mp 73°-76° C.
EXAMPLE E
4-(3-Quinolinyl)butan-1-ol
Step A: Preparation of 4-(3-Quinolinyl)-3-butyn-1-ol
A solution of 3-bromoquinoline (13.57 mL, 0.10 mol) and 3-butyn-1-ol (9.0 mL, 0.12 mol) in 40 mL of triethylamine and 75 mL of dichloromethane is degassed by bubbling dry nitrogen through it for 15 minutes, and 0.7 g (0.001 mol) of bis(triphenylphosphine)palladium dichloride and 0.013 g of cuprous iodide are added. The flask is flushed with nitrogen and the mixture heated to reflux for 5 hours. The cooled mixture is diluted with dichloromethane and washed with water, dried (sodium sulfate), and concentrated to give 27 g of a gold oil. The oil was triturated with diethyl ether to give 18.2 g of the title compound as a tan solid; mp 95.7°-96.7° C.
Step B: Preparation of 4-(3-Quinolinyl)butan-1-ol
A solution of 4-(3-quinolinyl)-3-butyn-1-ol (17.0 g, 0.086 mol) is hydrogenated over palladium on carbon (1.0 g) in ethanol (400 mL) at room temperature. After the catalyst is filtered, the solvent is removed under reduced pressure to give 17.3 g of a brown oil. The oil is chromatographed (silica gel, 2% methanol/98% dichloromethane) to give 13.5 g of the title compound as a yellow oil.
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Substituted tetrahydropyridines and derivatives thereof are described, as well as methods for the preparation and pharmaceutical composition of same, which are useful as central nervous system agents and are particularly useful as dopaminergic, antipsychotic, and antihypertensive agents as well as for treating hyperprolactinaemia-related conditions and central nervous system disorders.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of Korean Patent Application No. 2004-40001, filed on Jun. 2, 2004 in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an air purifier, and more particularly, to a freestanding air purifier in which a discharge direction of purified air can be varied.
[0004] 2. Description of the Related Art
[0005] Generally, a freestanding air purifier defines a flow path around an axial flow fan vertically mounted therein for intaking and discharging ambient air, and has a filter provided at an intake port for filtrating contaminants present in ambient air. This type of air purifier is referred to as a freestanding air purifier since its body has a vertically extended shape.
[0006] In such a freestanding air purifier, a discharge port is formed at the opposite side of the intake port such that intake air at the intake port is purified by the filter and discharged to the opposite side thereof, and is formed with an auto-blade allowing a variation of a specified angle so as to vary a discharge angle of the purified air.
[0007] In the freestanding air purifier, an air-stream flows from the rear side of the air purifier provided with the intake port to the front side thereof provided with the discharge port. Here, although, in the case where the discharge angle of air is varied by means of the auto-blade, the variation of the air-stream is slight. As a result, the variation of the air-stream is considerably restricted, so that the overall air-stream is not significantly changed.
[0008] Accordingly, when indoor air is purified by the conventional air purifier as described above, there is a problem in that as the purified air is distributed mainly from the font side of the air purifier, the purified air is non-uniformly distributed depending on where the air purifier is positioned in an installation area, thereby making the degree of air pollution non-uniform in the installation area.
[0009] Furthermore, there is a problem in that, since the discharge of the purified air is concentrated in one direction, it takes a long time to purify the entire installation area, thereby lowering purification efficiency.
BRIEF SUMMARY
[0010] The present invention has been made in view of these and/or other problems involved with the above-mentioned conventional air purifier, and one aspect of the present invention is to provide an air purifier, which can allow a free variation in a discharge direction of purified air, thereby making degree of air pollution of an installation area uniform.
[0011] It is another aspect of the present invention to provide an air purifier, which can reduce time for purifying the installation area, thereby enhancing purification efficiency.
[0012] According to an aspect of the present invention there is provided an air purifier, including: a filter which removes contaminants from air flowing therethough; a fan which generates a flow force to pass through the filter; and a rotating body rotatably mounted in the air purifier and defining a flow path around the fan, a discharge direction of the flow path being varied b rotation of the rotating body.
[0013] The air purifier may include a driving motor which rotates the rotating body.
[0014] The rotating body may include a rear guide and a stabilizer therein, and the flow path may include an intake flow path through the filter, and a discharge flow path defined by the rear guide and the stabilizer.
[0015] The air purifier may further include a gear assembly which transfers a driving force of the driving motor to the rotating body.
[0016] The rotating body may include multiple rotating bodies so as to have two or more discharge directions.
[0017] The multiple rotating bodies may comprise first and second rotating bodies provided such that the first and second rotating bodies are located at upper and lower stages in the air purifier, respectively.
[0018] The first and second rotating bodies may be driven such that the first and second rotating bodies have an independent rotating direction, respectively.
[0019] The air purifier may include first and second driving motors in the body of the air purifier which respectively rotate the first and second rotating bodies.
[0020] The first and second rotating bodies may be driven such that the first rotating body rotates in relation to the second rotating body.
[0021] The air purifier may include a driving motor, the first rotating body may be directly mounted on the second rotating body, and the second rotating body may be rotated by the driving motor and thus drives the first rotating body.
[0022] An air purifier including: a rotating body defining an airflow path having an air intake section and an air exhaust section, the rotating body having a discharge direction extending from the air exhaust section; a filter assembly which removes contaminants in air passing therethrough and is disposed at the air intake section; a fan which generates an air flow to draw air into the airflow path through the intake section and around the fan. The discharge direction is variable by rotation of the rotating body.
[0023] An air purifier including: a body having a first and a second rotating bodies each having an airflow path between an air intake section and an air exhaust section thereof, each rotating body having a discharge direction extending from the air exhaust section and each rotating body being independently rotatable with respect to the other rotating body; a filter assembly which removes contaminants in air passing therethrough and is disposed at the air intake section of each rotating body; and a fan which generates an air flow to draw air into the airflow path through the intake sections and around the fan. The discharge direction of each rotating body is variable by rotation of the rotating body.
[0024] An air purifier including: a body having a first and a second rotating bodies each having an airflow path between an air intake section and an air exhaust section, each rotating body having a discharge direction extending from the air exhaust section thereof, the first rotating body being rotatable in relation to the second rotating body; a filter assembly which removes contaminants in air passing therethrough and is disposed at the air intake section of each rotating body; and a fan which generates an air flow to draw air into the airflow path through the intake sections and around the fan. The discharge direction of each rotating body is variable by rotation of the rotating body.
[0025] A method of purifying air, including: providing a rotating body which defines a flow path to intake air in an intake direction and to discharge air in a discharge direction; generating an air flow to intake air into the flow path and to discharge air from the flow path; and varying at least one of an intake direction and a discharge direction by rotating the rotating body.
[0026] Additional and/or other aspects and advantages of the present invention will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] These and/or other aspects and advantages of the invention will become apparent and more readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings of which:
[0028] FIG. 1 is a perspective view illustrating an air purifier according to a first embodiment of the present invention;
[0029] FIG. 2 is a cross-sectional view taken along line II-II of FIG. 1 ;
[0030] FIG. 3 is a cross-sectional view taken along line III-III of FIG. 1 ;
[0031] FIG. 4 is a perspective view illustrating an air purifier according to a second embodiment of the present invention;
[0032] FIG. 5 is a cross-sectional view taken along line V-V of FIG. 4 ;
[0033] FIG. 6 is a perspective view illustrating an air purifier according to a third embodiment of the present invention; and
[0034] FIG. 7 is a cross-sectional view taken along line VII-VII of FIG. 6 .
DETAILED DESCRIPTION OF EMBODIMENTS
[0035] 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.
[0036] FIGS. 1 to 3 show an air purifier according to a first embodiment of the present invention. Referrin to FIGS. 1-3 , the air purifier according to the first embodiment of the present invention includes a cylindrical body 100 standing upright, and a rotating body 140 rotatably mounted in the body 100 .
[0037] The body 100 comprises an upper body 110 provided with an operation part 111 for controlling the air purifier, a lower body 120 provided with a fulcrum 121 for supporting the body 100 so that it does not fall down, and a support 130 for connecting the upper and lower bodies 110 and 130 to each other. The operation part 111 is provided with an operation button 111 a for inputting a signal for operating the air purifier, and a display 111 b for displaying an operating state of the air purifier. The body 100 is provided at a specified position therein with a controller for controlling operation of each component according to an input from the operation part 111 .
[0038] An axial flow fan 101 is provided between the upper and lower bodies 110 and 120 , respectively, parallel to the central axis of the upper and lower bodies 110 and 120 . The top end of the axial flow fan 101 is slidably provided at a lower surface of the upper body 110 , and the lower end of the axial flow fan 101 is connected to a driving axis of a fan motor 102 for driving the axial flow fan 101 .
[0039] Referring to FIG. 3 , the rotating body 140 is provided around the axial flow fan 101 such that an intake flow path 141 and a discharge flow path 142 for air are defined around the center of the axial air fan 101 . As an entrance of the intake flow path 141 , there is provided an intake port 143 , which has a filter assembly 150 for removing dust, fumes, order and other contaminants suspended in the air.
[0040] The filter assembly 150 includes a filter 151 , and a filter case 152 for fixing the filter 151 . As for the filter 151 , a typical filter for an air purifier, in which an antibacterial pre-filter for filtrating relatively large dust particles, a dust collection filter for removing fine particles, and the like are collectively coupled to each other, is used. The filter 151 is mounted on the intake flow path 141 with an edge of the filter 151 fixed to the filter case 152 . The filter case 152 is provided with an intake grill such that air can be inhaled therethrough. It is preferable that the filter case 151 be detachably coupled to the intake flow path 141 for making it easy to replace or clean the filter 151 .
[0041] At the opposite side of the intake flow path 141 , the discharge flow path 142 is defined by a rear guide 145 and a stabilizer 146 , and at the rear end of the discharge flow path 142 , a discharge port 144 having a discharge grill is provided.
[0042] Approximate intake and discharge directions of air, defined by the structure of the flow path as described above, are indicated by an arrow A in FIG. 3 . Such a flow path can be varied by rotation of the rotating body 140 . The structure for varying the flow path is illustrated in FIG. 2 . Specifically, the upper body 110 is provided with a driving motor 148 for rotating the rotating body 140 . A driving force of the driving motor 148 is transferred to the rotating body 140 by a gear transmission. For this purpose, the driving motor 148 has a driving shaft formed with a pinion 149 , and the cylindrical rotating body 140 has a internal gear 147 engaging with the pinion 149 at the upper end in the rotating body 140 . The driving motor 148 employs a stepping motor, which can rotate in both clockwise and counter-clockwise directions, and is controlled by the controller. As the rotating body 140 rotates by the driving force of the driving motor 148 , the discharge direction of air can be freely varied, and the discharge direction of air is controlled such that air can be discharged in all directions from the body 100 . The upper and lower bodies 110 and 120 are provided with guide rails 112 and 122 at the bottom surface of the upper body 110 and at the top surface of the lower body 120 , respectively, for allowing the rotating body 140 to easily rotate.
[0043] Operation of the air purifier according to the first embodiment is described below.
[0044] When starting the air purifier through the operation part 111 , an airflow is generated with rotation of the axial flow fan 101 . Air is inhaled through the intake grill, and filtrated through the filter 151 , so that foreign substances in the air can be removed therefrom, providing purified air. The purified air is blown along the discharge flow path 142 by the axial flow fan 101 .
[0045] Operation of the driving motor 148 to vary a blowing direction of air causes the entire rotating body 140 to rotate, changing the positions of the intake flow path 141 and the discharge flow path 142 , so that the discharge direction of air is varied. According to control of the rotation by the driving motor 148 , air can be discharged in all directions from the body 100 , and the air contained in the installation area can be uniformly purified by continuously changing the discharge direction of the air.
[0046] An air purifier according to a second embodiment of the present invention will be described in detail with reference to FIGS. 4 and 5 below.
[0047] The air purifier according to the second embodiment has the same configuration as that of the air purifier according to the first embodiment, except that the air purifier according to the second embodiment has a rotating body divided into two parts on upper and lower stages in order to more variously change the discharge direction of purified air.
[0048] The air purifier according to the second embodiment includes a cylindrical body 200 standing upright, as in the case of the air purifier according to the first embodiment, and a first and second rotating bodies 240 and 270 , respectively, mounted on the upper and lower stages in the body 200 .
[0049] The body 200 comprises an upper body 210 provided with an operation part 211 for controlling the air purifier, a lower body 220 provided with a fulcrum 222 , an intermediate body 260 between the first and second rotating bodies 240 and 270 , and a support 230 for connecting them.
[0050] An axial flow fan 201 , which generates a flow force for intaking and discharging air, is provided between the upper and lower bodies 210 and 220 via the intermediate body 260 . The lower body 220 is provided with a fan motor 202 for driving the axial flow fan 201 .
[0051] Like the rotating body of the air purifier according to the first embodiment, the first and second rotating bodies 240 and 270 are defined with intake and discharge flow paths, respectively, and provided with filter assemblies, respectively, for removing foreign substances from the air.
[0052] The intermediate body 260 is provided with a first driving motor 248 for rotating the first rotating body 240 , and the lower body 220 is provided with a second driving motor 278 for rotating the second rotating body 270 , such that the first and second rotating bodies 240 and 270 , respectively, can vary intake and discharge directions of air relative to each other. The driving motors 248 and 278 have driving shafts formed with pinions 249 and 279 (shown in FIG. 2 ), respectively. The first and second rotating bodies 240 and 270 respectively have internal gears 247 and 277 respectively engaging with the pinions 249 and 279 at inner periphery surfaces of the lower ends of the rotating bodies 240 and 270 , respectively, thereby transferring a driving force through a gear transmission.
[0053] Operation of the air purifier according to the second embodiment is similar to that of the first embodiment. However, since the air purifier according to the second embodiment has the first and second rotating bodies 240 and 270 separated at the upper and lower stages, the rotational directions of the first and second rotating bodies 240 and 270 can be independently controlled, so that the purified air can be more uniformly distributed to respective positions of an installation area.
[0054] An air purifier according to a third embodiment of the present invention will be described in detail with reference to FIGS. 6 and 7 as follows.
[0055] The air purifier according to the third embodiment is a modification of that of the second embodiment. The air purifier according to the third embodiment is the same as that of the air purifier according to the second embodiment in that first and second rotating bodies 340 and 370 are provided at upper and lower stages of the air purifier. However, there is a difference between the first and second embodiments in that the first rotating body 340 can rotate in relation to the second rotating body 370 below the first rotating body 340 .
[0056] As shown in FIGS. 6 and 7 , the air purifier according to the third embodiment includes a body 300 having an operation part 311 for controlling the air purifier and a fulcrum 322 , and the first and second rotating bodies 340 and 370 mounted at the upper and lower stages in the body 300 .
[0057] An axial flow fan 301 , which generates a flow force for intaking and discharging air, is provided at the center between the first and second rotating bodies 340 and 370 , and fixed at the lower end of the axial flow fan 301 to a driving shaft of a fan motor 302 for driving the axial flow fan 301 .
[0058] Like the rotating bodies of the first and second embodiments, the first and second rotating bodies 340 and 370 are defined with intake flow paths and discharge flow paths, respectively, and provided with filter assemblies, respectively, for removing foreign substances in the air.
[0059] The body 300 is provided, at one side thereof, with a second driving motor 378 for driving the second rotating body 370 , such that the second rotating body 370 can vary intake and discharge directions of air. The second driving motor 378 has a driving shaft formed with a pinion 379 , and has an internal gear 377 engaging with the pinion 379 at an inner periphery surface of the lower end of the second rotating body 370 , thereby transferring a driving force through a gear transmission.
[0060] Unlike the air purifier according to the second embodiment, the first rotating body 340 is connectedly mounted on the second rotating body 370 . The second rotating body 370 is provided, at an upper portion in the second rotating body 370 , with a first driving motor 348 for driving the first rotating body 340 , and the first rotating body 340 is formed, at a lower portion thereof, with a coupling portion 347 , which is formed with an outer gear around an outer peripheral surface of the first rotating body 340 and extends through the upper end of the second rotating body 370 , such that the first rotating body 340 can rotate in relation to the second rotating body 370 . The first driving motor 348 has a driving shaft formed with a pinion 349 , thereby driving the first rotating body 340 through engagement of the pinion 349 with the outer gear of the coupling portion 347 .
[0061] Operation of the air purifier according to the third embodiment is similar to that of the second embodiment. However, the air purifier according to the second third embodiment has the first rotating body 340 , which can be driven in relation to the second rotating body 370 , so that the first rotating body 340 can be rotated by only driving the second driving motor 378 without driving the first driving motor 348 .
[0062] As is apparent from the above description, since the air purifier according to the described embodiments of the present invention is structured such that the rotating body defining the flow path around the blowing fan can be freely rotated, there is an advantageous effect in that the discharge direction of air can be freely varied, thereby uniformly distributing the purified air to an installation area.
[0063] Further, the intake and discharge directions of air for purifying the installation area can be varied, there is an advantageous effect in that time for purifying the installation area can be reduced, thereby enhancing purification efficiency.
[0064] Although a few embodiments of the present invention have been shown and described, it would be appreciated by those skilled in the art that changes may be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the claims and their equivalents.
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An air purifier including: a filter which removes contaminants from air passing therethrough; a fan which generates a flow force to pass air through the filter; and a rotating body rotatably mounted in the air purifier and defining a flow path around the fan, a discharge direction of the flow path being varied by rotation of the rotating body.
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FIELD OF THE INVENTION
The present invention relates to inflatable packers for use during the drilling or production of oil and gas wells for the purpose of providing an annular seal between the outside of the pipe string and the surrounding surface such as a borehole wall or the inner surface of a larger pipe. More particularly, the present invention relates to inflatable packers having inflatable elastomer sleeves usually of 5 to 40 feet in length for inflation in a wellbore by means of a cement slurry introduced during the cementing operation.
BACKGROUND OF THE INVENTION
Inflatable rubber or elastomer sleeve type packers having a relatively short length elastomer sleeve have been in use for many years. The elastomer sleeve of this type of packer has reinforcing ribs which extend continuously along the length of the sleeve. The reinforcing ribs, inter alia, are incorporated into the sleeve and prevent any portion of the sleeve from moving axially with respect to its supporting mandrel while the packer is being run into the wellbore on a string of pipe. However, as the length of the sleeve and supporting mandrel or pipe has increased to provide extended length inflatable packers up to forty feet in length (a common length of pipe), the use of continuous ribs along the length of the sleeve is impractical. As a result the central portions of the sleeve do not have any support ribs and the unsupported sleeve has a tendency to move axially with respect to its supporting mandrel while the packer is being run into the well. This can result in failure of the sleeve and therefore subsequent loss of the sealing and anchoring ability of the packer when expansion of the sleeve is attempted. When damage to the sleeve occurs, the pipe string may have to be retrieved before the cementing operation to replace the packer which involves expensive delays in the drilling and completion of oil and gas wells.
Movement of the sleeve axially with respect to its supporting mandrel before the inflation of sleeve may be caused by several factors; i.e., the string of pipe which includes the packer may move laterally against the side of the borehole causing frictional contact of the sleeve with the borehole; the borehole may not be straight causing frictional contact of the sleeve with the borehole, the borehole may have cuttings stacked within it so as to force the sleeve on the string of pipe to contact the borehole wall; or the supporting mandrel in the string of pipe may be in compression and cause the sleeve to frictionally contact the borehole wall. Any one of the above factors when occurred in a wellbore can cause axial movement between the sleeve and its supporting mandrel before the packer is at its desired location and inflated. The axial movement can cause the sleeve to tear away and prevent it from providing its intended function of sealing and anchoring against the borehole. The tendency for a long sleeve to slide along the mandrel is much greater than for a short sleeve because of the longer length of contact between the sleeve and borehole and also because the sleeve lacks supporting ribs in its midsection.
Where the supporting mandrel in the string of pipe has a smooth outer surface, the contact of the sleeve of the borehole wall may develop a greater frictional force on the sleeve than the frictional force tending to hold the sleeve to a smooth mandrel.
One solution to the problem is presented in U.S. Pat. No. 4,311,314 dissued to George O. Suman. This patent discloses that a layer of material having a rough surface can be interposed between the steel supporting mandrel and the rubber sleeve. The rough surface material is formed by bonding solid grit-like particles (sand, metal or the like) to the mandrel surface by a suitable binder such as an epoxy resin. The rough surface of the epoxy impregnated bonding material provides for increased friction on the surface contacting the sleeve and therefore improves the frictional relationship of the sleeve relative to the supporting mandrel so that the sleeve is less likely to move axially with respect to the supporting mandrel. However, the addition of the epoxy and grit-like material to the supporting mandrel affects the acoustical transmission properties of the supporting mandrel. Thus, when a packer is inflated in the well into sealing contact with the wellbore and a cement bond logging or log (CBL) tool is run through the pipe to obtain a cement bond log, it has been found that the amplitude of the sonic signal on the CBL log obtained by the CBL tool is increased, which typically indicates a lack of bonding of cement at the interfaces between the cement and the borehole and mandrel. This increase in amplitude, however, is an erroneous representation because the amplitude of the sonic signal is affected by the epoxy and grit-like material. Therefore, a customer has an uncertainty about the bonding of the cement at the interfaces along the packer.
In an effort to solve the problem of the effects of the epoxy impregnated bonded material to the CBL logs and to obtain sufficient frictional coefficients between the mandrel and the midportion of a rubber sleeve, there is disclosed in U.S. application Ser. No. 460,313 filed Jan. 24, 1983 by William T. Bell et al, an inflatable packer wherein the supporting mandrel is grooved or knurled along its length to provide roughness between the mandrel and the sleeve. The rough surface of the mandrel enhances the ability of the packer to survive the trip in the wellbore without movement of the sleeve relative to its supporting mandrel. When the packer is inflated in the wellbore there is no epoxy material to adversely affect the results obtained by a CBL log with a CBL tool. However, the cost of knurling and of preparing the mandrel as such within the wall thickness standards required a pipe is expensive and the degree of frictional contact between a sleeve and a metal roughened mandrel is not necessarily as great as can be obtained by an epoxy grit material.
The present invention involves the use of a specially prepared mandrel for supporting the elastomer sleeve in which the advantages of the epoxy rough coating are retained and the adverse effects of the epoxy rough coating to the logs obtained by a CBL tool are eliminated.
SUMMARY OF THE INVENTION
The present invention is in an inflatable packer having a central steel mandrel and an elastomer sleeve on the mandrel movable between a first condition where the inner surface of the sleeve is in contact with the mandrel and a second condition where the outer surface of the sleeve is in contact with the borehole. Means are provided for admitting a cement slurry from the interior of the mandrel to inflate the sleeve from the first condition to the second condition. The length of the mandrel portion underlying the sleeve has intermittent coatings of grit-like particles bonded to the mandrel leaving intermittent bare portions of the mandrel, the intermittent coatings serving to prevent relative axial movement between the sleeve and the mandrel while going into the borehole and the intermittent bare portions of the mandrel serving to affect the sound transmission properties of the mandrel so that a cement bond log can be obtained. The spacing of the intermittent coatings and bare portions of the mandrel is related to the transmitter and receiver of a cement bond logging tool.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a typical cement bond log obtained by a cement bond logging tool in a wellbore containing an inflatable packer with a mandrel having a continuous grit particle coating;
FIG. 2 illustrates a packer constructed in accord with the present invention; and
FIG. 3 is an enlarged fragmentary view taken from FIG. 1 to illustrate grit-like particles bonded to the mandrel.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, a typical CBL log is illustrated for background purposes. The log is a plot of various measurements made by the tool as a function of depth. Curve A on the log is a typical gamma ray log obtained by a gamma ray tool. Curve B is a travel time log which indicates the ΔT or time required for a sonic signal to travel through a known length of casing. Curve C is a casing collar log obtained by a magnetic collar locator to indicate collar locations along the length of the string of pipe. On the right hand side of the log, the curve D indicates a plot of the amplitude of the measured sonic signal in a CBL tool and the line E represents the reference line at which the indication of bonding is measured.
As can be appreciated from the log, the curve D at the location 10 indicates a lack of bonding between points 11 and 12 which correspond to the locations of the upper and lower collars of an inflatable packer extending between the depths of 6054' and 6094'. The inflatable packer utilized a continuous epoxy grit coating and thus, the CBL log does not give an indication of the degree of bonding within the inflatable packer.
Referring to a reference line 15 drawn between depths of 6054' and 6094' on the curve B, the reference line 15 illustrates average travel time through a casing or pipe. The sonic travel time in casing as shown by curve B is increased further indicating the effect of the rough coating on the sonic signal. By use of the present invention, the log of travel time obtained by the CBL tool will not be distorted nor the amplitude measurements at location 10 which indicate bonding be disturbed.
Referring now to FIG. 2, the present invention is illustrated. A tubular mandrel or pipe 12 made of metal or the like provides a support for a tubular sleeve 16 made of a suitable elastomer for use in an oil well. The sleeve 16 is positioned along the length of the mandrel and sealingly fixed to the mandrel 12 at collars 13 and 14. Collar 13 contains a valve system 18 which provides communication of fluid from a bore 20 of the mandrel 12 into an annular space formed between the mandrel and sleeve. The collars 13 and 14 are threadedly and sealingly coupled to a string of pipe above and below the packer. Along the length of the outer surface of the mandrel 12 are intermittent epoxy coatings 15 containing grit-like materials. The coatings 15 are provided in one foot lengths with one foot of spacing between adjacent coatings along the length of the mandrel for reasons which will be made more apparent later. With the rough surface coatings 15 intermittently along the mandrel, while the packer is being lowered into the borehole, the rough surface on the mandrel will prevent the elastomer of the sleeve from shifting or moving with respect to the length of the mandrel. The sleeve 16 is also provided with end ribs 17 which are made of metal or the like and positioned in the upper and lower ends of the sleeve, around and parallel to the mandrel 12 so as to provide end support for the sleeves during and after inflation of the sleeve 16.
The rough coated surfaces 15 on the mandrel are provided by bonding solid grit-like particles (sand, metal or the like) to the mandrel surface by a suitable binder such as epoxy resin and with a suitable thickness. Thus, as shown in FIG. 3, the outer surface 23 of the epoxy resin 19 has particles of sand or flint 21 mixed with or added thereto so as to provide a sandpaper like roughness to indent the elastomer on the sleeve 16 and to cause the sleeve to adhere to the mandrel while it is being moved through a borehole and thereby prevent damage to the sleeve while its being run into the wellbore.
Referring again to FIG. 2, a CBL tool 30 is illustrated with a transmitter T and receivers R1 and R2. The transmitter to receiver (TR 1 ) spacing is typically three feet and the spacing between receivers R1 and R2 is two feet. By adjusting the length of the rough coatings 15 on the mandrel to one foot and the spacing between the rough coatings 15 to one foot, it can be assured that in any three foot interval between the transmitter there will be at least one foot of uncoated or bare mandrel.
It will be appreciated that the TR 1 spacing commonly in use at present is three feet, that this spacing may be varied and thus the spacing of two coating segments and a bare portion on the mandrel may vary accordingly.
In the operation of a CBL, the tool is typically designed to sense a selected peak amplitude at each of the receivers. Heretofore, the presence of a continuous grit-like coating has caused the selected peak amplitude to be increased because of the effect of the continuous epoxy coating. By use of the discontinuous coatings, the bare portion of the mandrel removes the increased effect of the sound transmission in the coating and effectively permits the proper peak amplitude to be sensed. Thus, the advantages of the rough coating to prevent relative axial movement of the sleeve and mandrel are obtained and the packer will not adversely affect a CBL log.
It will be apparent to those skilled in the art that various changes may be made in the invention without departing from the spirit and scope thereof and therefore the invention is not limited by that which is enclosed in the drawings and specifications but only as indicated in the appended claims.
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An inflatable packer with a supporting mandrel having intermittent coatings of grit-like materials bonded to the mandrel to provide a frictional contact surface for an inflatable rubber sleeve with intermittent bare portions thereby to permit use of a cement bond logging tool, the spacings of the coatings being functionally related to the transmitter/receiver spacing of a cement bond logging tool.
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FIELD OF THE INVENTION
[0001] This invention relates to arylated camphenes, processes for their preparation and uses thereof for the manufacture of medicaments for the treatment of diseases, disorders or conditions associated with, or benefiting from stimulation of CB2 receptors.
BACKGROUND OF THE INVENTION
[0002] The following publications are relevant for describing the state of the art in the
field of the invention:
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[0028] 26. Pacher P, Haskó G. Endocannabinoids and cannabinoid receptors in ischaemia-reperfusion injury and preconditioning. Br J Pharmacol. 153:252-62 (2008).
[0029] 27. Palazuelos J, Aquado T, Egia A, Mechoulam R, Guzman M, Galve-Roperh I. Non-psychoactive CB2 cannabinoid agonists stimulate neural progenitor proliferation. FASEB J. 580, 4337-4345 (2006).
[0030] 28. Palazuelos J, Davoust N, Julien B, Hatterer E, Aguado T, Mechoulam R, Benito C, Romero J, Silva A, Guzman M, Nataf S, Galve-Roperh I. The CB2 cannabinoid receptor controls myeloid progenitor trafficking. Involvement in the pathogenesis of an animal model of multiple sclerosis. J Biol Chem. 283, 13320-13329 (2008).
[0031] 29. Steffens S, Mach F. Cannabinoid receptors in atherosclerosis. Curr. Opinion Lipidology, 17, 519-526, 2006.
[0032] 30. Steffens S, Veillard N R, Arnaud C, Pelli G, Burger F, Staub C, Karsak M, Zimmer A, Frossard J L, Mach F. Low dose oral cannabinoid therapy reduces progression of atherosclerosis in mice. Nature 434, 782-786 (2005).
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[0037] 35. Pertwee R G, Gibson T M, Stevenson L A, Ross R A, Banner W K, Saha B, Razdan R K and Martin B R. 0-1057, a potent water-soluble cannabinoid receptor agonist with antinociceptive properties. Br J Pharmacol. 129, 1577-1584 (2000).
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[0041] Two cannabinoid receptors have been well characterized so far—the CB 1 receptor, which is present mainly in the central nervous system (CNS), (and to a lesser extent in the periphery), and the CB2 receptor which is considered mainly a peripheral receptor. Natural stimulation of the CB 1 receptor, which is produced by the endogenous cannabinoids, when and where needed, is central to many of our physiological systems. However exogenous administration of CB 1 agonists (such as the marijuana constituent THC) may lead to undesirable side effects. Therefore CB 1 agonists, which act on the central nervous system, are of limited therapeutic value (for a recent review see Kogan and Mechoulam, 2007).
[0042] The CB2 receptor is present in low levels in the CNS, mainly in glial cells. However, numerous neurological conditions have been shown to induce expression of this receptor in the brain. Some of these conditions are cerebral hypoxia-ischemia, cerebral artery occlusion, Alzheimer's disease and Huntington's disease. It was further shown that stimulation of the CB2 receptor is not accompanied by undesirable CNS or other effects, such as major and/or detrimental psychoactive effects, usually associated with the stimulation of the CB1 receptor (Ashton and Glass, 2007).
[0043] There is therefore a need for selective CB2 receptor stimulants, capable of being utilized for treating diseases, disorders or conditions associated with, or benefiting from such stimulation of CB2 receptors.
SUMMARY OF THE INVENTION
[0044] The present invention provides a compound of general formula (I):
[0000]
[0045] wherein
[0046] 1 2, 2 3, 3 4 are each independently a single or double bond;
[0047] R a is selected from straight or branched C 1 -C 5 alkyl, straight or branched C 2 -C 5 alkenyl, straight or branched C 2 -C 5 alkynyl and —C(═O)R d , each optionally substituted by at least one group selected from —OH, —COOH, —NH 2 , C 1 -C 5 amine, halogen, phenyl, heteroaryl; wherein
R d is selected from the group consisting of —H, —OH, straight or branched C 1 -C 5 alkyl, straight or branched C 2 -C 5 alkenyl, straight or branched C 2 -C 5 alkynyl, straight or branched C 1 -C 5 alkoxy, —NR e R f ; R e and R f are each independently selected from H and straight or branched C 1 -C 5 alkyl; and
[0050] R b and R e are each independently selected from —H, —OH, ═O, ═CR g R h , ═NR i , ═S, —C 5 -C 15 , aryl ring substituted by at least one group selected from a straight or branched C 1 -C 12 alkyl, C 2 -C 12 alkenyl, C 2 -C 12 alkynyl, C 1 -C 12 alkoxy, amine, C 1 -C 12 alkoxycarboxylic acid, —OH, —OC(═O)R p and —C(═O)R q ; wherein
R g , R h , R p and R q are each independently selected from H, straight or branched C 1 -C 5 alkyl, straight or branched C 1 -C 5 alkoxy and NH 2 ; and provided that at least one of R b and R c is said substituted —C 5 -C 15 aryl ring.
[0052] In some embodiments of the invention at least one of 1 2, 2 3, 3 4 is a double bond.
[0053] In one embodiment of the present invention, 2 3 of compound of formula (I) is a double bond. Consequently, compound of formula (I) is a compound of formula (I′):
[0000]
[0054] wherein substituents R a , R b and R c are as defined herein above.
[0055] In another embodiment of the present invention, 2 3 of a compound of formula (I) is a single bond. Consequently, compound of formula (I) is a compound of formula (I″):
[0000]
[0056] wherein substituents R a , R b and R c are as defined herein above.
[0057] In one embodiment, 1 2 is a double bond. According to this embodiment, 2 3 is a single bond and 3 4 may be either a single or double bond.
[0058] In another embodiment, 3 4 is a double bond. According to this embodiment, 2 3 is a single bond and 1 2 may be either a single or double bond.
[0059] In a further embodiment 1 2 is a single bond and 3 4 is a single bond.
[0060] In another embodiment of the invention, at least one of R b and R c is a phenyl ring substituted by at least two substituent selected from a straight or branched C 1 -C 12 alkyl, C 2 -C 12 alkenyl, C 2 -C 12 alkynyl, C 1 -C 12 alkoxy, C 1 -C 12 alkoxycarboxylic acid, —C(═O)OH, —C(═O)NH 2 , —C(═O)(C 1 -C 50 alkyl), —C(═O)(C 1 -C 5 alkoxy), —OC(═O)H, —OC(═O)NH 2 , —OC(═O)(C 1 -C 5 alkyl). Thus, in one embodiment R b is a phenyl ring substituted by at least two substituent selected from a straight or branched C 1 -C 12 alkyl, C 2 -C 12 alkenyl, C 2 -C 12 alkynyl, C 1 -C 12 alkoxy, amine, C 1 -C 12 alkoxycarboxylic acid, —COOH, —CONH 2 , —C(═O)(C 1 -C 5 alkyl), —C(═O)(C 1 -C 5 alkoxy), —OCOH, —OC(═O)NH 2 , —OC(═O)(C 1 -C 5 alkyl) and R c is selected from —H, —OH, ═O, ═CR g R h , ═NR i , ═S, —C s -C 5 -C 15 aryl ring substituted by at least one group selected from a straight or branched C 1 -C 12 alkyl, C 2 -C 12 alkenyl, C 2 -C 12 alkynyl, C 1 -C 12 alkoxy, amine, C 1 -C 12 alkoxycarboxylic acid, —OC(═O)R p and —C(═O)R q ; wherein R g , R h , R i R p and R q are each independently selected from H, straight or branched C 1 -C 5 alkyl, straight or branched C 1 -C 5 alkoxy and NH 2 . In another embodiment, R c is a phenyl ring substituted by at least two substituent selected from a straight or branched C 1 -C 12 alkyl, C 2 -C 12 alkenyl, C 2 -C 12 alkynyl, C 1 -C 12 alkoxy —COOH, —CONH 2 , —C(═O)(C 1 -C 5 alkyl), —C(═O)(C 1 -C 5 alkoxy), —OCOH, —OC(═O)NH 2 , —OC(═O)(C 1 -C 5 alkyl) and R b is selected from —H, —OH, ═O, ═CR g R h , ═NR i , ═S, —C 5 -C 15 aryl ring substituted by at least one group selected from a straight or branched C 1 -C 12 alkyl, C 2 -C 12 alkenyl, C 2 -C 12 alkynyl, C 1 -C 12 alkoxy, amine, C 1 -C 12 alkoxycarboxylic acid, —OC(═O)R p and —C(═O)R q ; wherein R g , R h , R i R p and R q are each independently selected from H, straight or branched C 1 -C 5 alkyl, straight or branched C 1 -C 5 alkoxy and —NH 2 .
[0061] In another embodiment of the invention, at least one of R b and R c is a phenyl ring substituted by at least three substituent selected from a straight or branched C 1 -C 12 alkyl, C 2 -C 12 alkenyl, C 2 -C 12 alkynyl, C 1 -C 12 alkoxy, —C(═O)OH, —C(═O)NH 2 , —C(═O)(C 1 -C 5 alkyl), —C(═O)(C 1 -C 5 alkoxy), —OC(═O)H, —OC(═O)NH 2 , —OC(═O)(C 1 -C 5 alkyl).
[0062] In some embodiments of the invention when all of 1 2, 2 3, 3 4 represent a single bond, at least one of R b and R c is a —C 5 -C 15 aryl ring being substituted by at least two substituents selected from a straight or branched C 1 -C 12 alkyl, C 2 -C 12 alkenyl, C 2 -C 12 alkynyl, C 1 -C 12 alkoxy, amine, C 1 -C 12 alkoxycarboxylic acid, —OC(═O)R p and —C(═O)R q ; wherein R g , R h , R p and R q are each independently selected from H, straight or branched C 1 -C 5 alkyl, straight or branched C 1 -C 5 alkoxy and NH 2 .
[0063] In other embodiments, of the invention when all of 1 2, 2 3, 3 4 represent a single bond, at least one of R b and R c is a —C 5 -C 15 aryl ring being substituted by at least three substituents selected from a straight or branched C 1 -C 12 alkyl, C 2 -C 12 alkenyl, C 2 -C 12 alkynyl, C 1 -C 12 alkoxy, amine, C 1 -C 12 alkoxycarboxylic acid, —OC(═O)R p and —C(═O)R q ; wherein R g , R h , R p and R q are each independently selected from H, straight or branched C 1 -C 5 alkyl, straight or branched C 1 -C 5 alkoxy and NH 2
[0064] In another embodiment of the present invention, at least one of R b and R c is a group of formula (II):
[0000]
[0065] wherein R j and R k are each independently selected from H, and —OR n wherein R n is selected form H, —COOR t , a straight or branched C 1 -C 5 alkyl optionally substituted by at least one group selected from —COOH, —NH 2 , provided that at least one of R j and R k is different than H; and R m is selected from a straight or branched C 6 -C 12 alkyl, a straight or branched C 5 -C 9 alkoxy, a straight or branched C 1 -C 7 ether; each optionally substituted by at least one group selected from —COOH, —NH 2 ; and R t is selected from H, C 1 -C 5 alkyl and —NH 2 .
[0066] Thus, a compound of the invention may be a compound of any one formulae (III), (IV), (V) or (VI):
[0000]
[0067] wherein R j and R k are each independently H or —OR n wherein R n is selected from H, —COOR t , a straight or branched C 1 -C 5 alkyl optionally substituted by at least one group selected from —COOH, —NH 2 , provided that at least one of R j and R k is different than H; and R m is a straight or branched C 6 -C 12 alkyl and R t is selected from H, C 1 -C 5 alkyl and —NH 2 .
[0068] In another embodiment of the present invention, R a is selected from an straight or branched C 1 -C 5 alkyl and —C(═O)R d , each optionally substituted by at least one group selected from —OH, —COOH, —NH 2 , C 1 -C 5 amine, halogen, phenyl, heteroaryl and R d is as defined herein above.
[0069] In another embodiment of the present invention, at least one of R b and R c is a group of formula (II′) or (II″):
[0000]
[0070] wherein R j , R k and R mm are each independently selected from H, and —OR n wherein R n is selected form H. —COOR t , a straight or branched C 1 -C 5 alkyl optionally substituted by at least one group selected from —COOH, —NH 2 , provided that at least one of R j and R k is different than H; and R m is selected from an optionally substituted straight or branched C 3 -C 12 alkyl, an optionally substituted straight or branched C 5 -C 9 alkoxy, an optionally substituted straight or branched C 1 -C 7 ether; and R t is selected from H, C 1 -C 5 alkyl and —NH 2 .
[0071] In a further embodiment of a compound of formula (I), when 2 3 is a single bond, R b and R c are each independently selected from —H, —OH, ═O, ═CR g R h , ═NR j , ═S, —C 5 -C 15 aryl ring substituted by at least two substituent selected from a straight or branched C 1 -C 12 alkyl, C 2 -C 12 alkenyl, C 2 -C 12 alkynyl, C 1 -C 12 alkoxy, amine, —OC(═O)R p and —C(═O)R q ; wherein R g , R h , R p and R q are each independently selected from H, straight or branched C 1 -C 5 alkyl, straight or branched C 1 -C 5 alkoxy and —NH 2 ; and provided that at least one of R b and R c is said substituted —C 5 -C 15 aryl ring. In a further embodiment, said R b is 50 O, thus a compound of the invention may be a compound of formula (VII), wherein R c is said substituted —C 5 -C 15 aryl ring:
[0000]
[0072] In yet a further embodiment, R c is ═O, thus a compound of the invention may be a compound of formula (VIII), wherein R b is said substituted —C 5 -C 15 aryl ring:
[0000]
[0073] In one embodiment, a compound of the invention is selected from the following list:
methyl-2-(2,6-dimethoxy-4-(2-methyloctan-2-yl)phenyl)-7,7-dimethylbicyclo[2.2.1]hept-2-ene-1-carboxylate; methyl-2-(2,6-dimethoxy-4-pentylphenyl)-7,7-dimethylbicyclo[2.2.1]hept-2-ene-1-carboxylate; 2-(2,6-dimethoxy-4-(2-methyloctan-2-yl)phenyl)-1,7,7-trimethylbicyclo[2.2.1]hept-2-ene; (2-(2,6-dimethoxy-4-(2-methyloctan-2-yl)phenyl)-7,7-dimethylbicyclo[2.2.1]hept-2-en-1-yl)methanol; (2-(2,6-dimethoxy-4-pentylphenyl)-7,7-dimethylbicyclo[2.2.1]hept-2-en-1-yl)methanol; 2-(2,6-dimethoxy-4-(2-methyloctan-2-yl)phenyl)-7,7-dimethylbicyclo[2.2.1]hept-2-ene-1-carboxylic acid; 2-(2,6-dimethoxy-4-pentylphenyl)-7,7-dimethylbicyclo[2.2.1]hept-2-ene-1-carboxylic acid; 3-(2,6-dimethoxy-4-(2-methyloctan-2-yl)phenyl)-1,7,7-trimethylbicyclo[2.2.1]hept-2-ene; 3-(2,6-dimethoxy-4-pentylphenyl)-1,7,7-trimethylbicyclo[2.2.1]heptan-2-one; 3-(2,6-dimethoxy-4-(2-methyloctan-2-yl)phenyl)-1,7,7-trimethylbicyclo[2.2.1]heptan-2-one; 3-(2,6-dimethoxy-4-pentylphenyl)-1,7,7-trimethylbicyclo[2.2.1]heptan-2-ol; 3-(2,6-dimethoxy-4-(2-methyloctan-2-yl)phenyl)-1,7,7-trimethylbicyclo[2.2.1]heptan-2-ol (3-(2,6-dimethoxy-4-(2-methyloctan-2-yl)phenyl)-7,7-dimethylbicyclo[2.2.1]hept-2-en-1-yl)methanol; 3-(2,6-dimethoxy-4-(2-methyloctan-2-yl)phenyl)-7,7-dimethylbicyclo[2.2.1]hept-2-ene-1-carboxylic acid; methyl 3-(2,6-dimethoxy-4-(2-methyloctan-2-yl)phenyl)-7,7-dimethylbicyclo[2.2.1]hept-2-ene-1-carboxylate; (3-(2,6-dimethoxy-4-pentylphenyl)-7,7-dimethylbicyclo[2.2.1]hept-2-en-1-yl)methanol; 3-(2,6-dimethoxy-4-pentylphenyl)-7,7-dimethylbicyclo[2.2.1]hept-2-ene-1-carboxylic acid; 5-(2-methyloctan-2-yl)-2-(4,7,7-trimethylbicyclo[2.2.1]hept-2-en-2-yl)benzene-1,3-diol; 2-(4-(hydroxymethyl)-7,7-dimethylbicyclo[2.2.1]hept-2-en-2-yl)-5-(2-methyloctan-2-yl)benzene-1,3-diol; 3-(2,6-dihydroxy-4-(2-methyloctan-2-yl)phenyl)-7,7-dimethylbicyclo[2.2.1]hept-2-ene-1-carboxylic acid; 2-(4-(hydroxymethyl)-7,7-dimethylbicyclo[2.2.1]heptan-2-yl)-5-(2-methyloctan-2-yl)benzene-1,3-diol; 5-(2-methyloctan-2-yl)-2-(4,7,7-trimethylbicyclo[2.2.1]heptan-2-yl)benzene-1,3-diol; and 3-(2,6-dihydroxy-4-(2-methyloctan-2-yl)phenyl)-7,7-dimethylbicyclo[2.2.1]heptane-1-carboxylic acid.
[0097] The invention further provides a compound of general formula (I):
[0000]
[0098] wherein
[0099] 1 2, 2 3, 3 4 are each independently a single or double bond;
[0100] R a is selected from an straight or branched C 1 -C 5 alkyl, straight or branched C 2 -C 5 alkenyl, straight or branched C 2 -C 5 alkynyl and ‘ 3 C(═O)R d , each optionally substituted by at least one group selected from —OH, —COOH, —NH 2 , C 1 -C 5 amine, halogen, phenyl, heteroaryl; wherein R d is selected from the group consisting of —H, —OH, straight or branched C 1 -C 5 alkyl, straight or branched C 2 -C 5 alkenyl, straight or branched C 2 -C 5 alkynyl, straight or branched C 1 -C 5 alkoxy, —NR e R f ;
R e and R f are each independently selected from H and straight or branched C 1 -C 5 alkyl; and
[0102] R b and R e are each independently selected from —H, —OH, ═O, ═CR g R h , ═NR i , ═S, ═C 5 -C 15 aryl ring substituted by at least one group selected from a straight or branched C 1 -C 12 alkyl, C 2 -C 12 alkenyl, C 2 -C 12 alkynyl, C 1 -C 12 alkoxy, amine, C 1 -C 12 alkoxycarboxylic acid, —OH, —OC(═O)R p and —C(═O)R q ; wherein R g , R h , R p and R q are each independently selected from H, straight or branched C 1 -C 5 alkyl, straight or branched C 1 -C 5 alkoxy and —NH 2 ;
[0103] or R a and R b may form a ring together with the carbon atoms they are each attached to; said ring may be a cycloalkyl, cycloheteroalkyl, cycloheteroalkenyl, cycloalkenyl, cycloalkynyl, cycloheteroalkynyl ring; in some embodiments said ring is a 6 to 12 member ring;
[0104] provided that at least one of R h and R e is said substituted -C 5 -C 15 aryl ring.
[0105] In some embodiments, a compound of the invention has the general formula (XII):
[0000]
[0106] wherein is a single or double bond;
[0107] R c is selected from —H, —OH, ═O, ═CR g R h , ═NR 1 , ═S, —C 5 -C 15 aryl ring substituted by at least one group selected from a straight or branched C 1 -C 12 alkyl, C 2 -C 12 alkenyl, C 2 -C 12 alkynyl, C 1 -C 12 alkoxy, amine, C 1 -C 12 alkoxycarboxylic acid, —OC(═O)R p and —C(═O)R q ; wherein R g , R h , R p and R q are each independently selected from H, straight or branched C 1 -C 5 alkyl, straight or branched C 1 -C 5 alkoxy and —NH 2 ;
[0108] R j is selected from H, and —OR n wherein R n is selected form H, —COOR t , a straight or branched C 1 -C 5 alkyl optionally substituted by at least one group selected from —COOH, —NH 2 ; and R t is selected from H, C 1 -C 5 alkyl and —NH 2 ;
[0109] R m is selected from a straight or branched C 6 -C 12 alkyl, a straight or branched C 5 -C 9 alkoxy, a straight or branched C 1 -C 7 ether; each optionally substituted by at least one group selected from —COOH, —NH 2 ;
[0110] Z 1 and Z 2 are each independently selected from —O—, straight or branched C 1 -C 5 -alkylene, —S—, —C(═O)— and —C(═S)—.
[0111] In other embodiments, a compound of the invention may be selected from the group consisting of:
[0000]
[0112] As used herein, the term “alkyl” refers to a straight or branched chain hydrocarbon having from one to five carbon atoms, or from one to seven carbon atoms, or from five to nine carbon atoms, or from six to twelve carbon atoms. Examples of “alkyl” as used herein include, but are not limited to, methyl, ethyl, propyl, n-butyl, n-pentyl, isobutyl, and isopropyl, tert-butyl, and the like.
[0113] As used herein, the term “alkenyl” represents a branched or straight hydrocarbon group having from 2 to 5 or from 2 to 12 carbon atoms and at least one double bond. Examples of such groups include, but are not limited to, ethenyl, 1-propenyl, 2-propenyl, isopropenyl, 1,3-butadienyl, 1-butenyl, 2-butenyl, 1-pentenyl, 2-pentenyl, 1-hexenyl, 2-hexenyl and the like.
[0114] As used herein, the term “alkynyl” represents a branched or straight hydrocarbon group having from 2 to 5 or from 2 to 12 carbon atoms and at least one triple bond. Examples of such groups include, but are not limited to, ethynyl, 1-propynyl, 2-propynyl, 1-butynyl, 2-butynyl, 1-pentynyl, 2-pentynyl, 1-hexynyl, 2-hexynyl and the like.
[0115] As used herein the term “aryl” refers to aromatic monocyclic or multicyclic groups containing from 5 to 15 carbon atoms. Aryl groups include, but are not limited to groups such as unsubstituted or substituted fluorenyl, unsubstituted or substituted phenyl, and unsubstituted or substituted naphthyl. When referring to said aryl being substituted, said substitution may be at any position on the ring, other than the point of attachment to the other ring system of a compound of the invention. Therefore, any hydrogen atom on the aryl ring may be substituted with a substituent defined by the invention. In embodiments where the aryl is a phenyl ring, said substitution may be at the meta- and/or ortho- and/or para-position relative to the point of attachment.
[0116] As used herein the term “heteroaryl” refers to a monocyclic or multicyclic aromatic ring system, in certain embodiments, of about 5 to about 15 members where one or more, in one embodiment 1 to 3, of the atoms in the ring system is a heteroatom, that is, an element other than carbon, including but not limited to, nitrogen, oxygen or sulfur. The heteroaryl group may be optionally fused to a benzene ring. Heteroaryl groups include, but are not limited to, furyl, imidazolyl, pyrimidinyl, tetrazolyl, thienyl, pyridyl, pyrrolyl, thiazolyl, isothiazolyl, oxazolyl, isoxazolyl, triazolyl, quinolinyl and isoquinolinyl,
[0117] As used herein, the term “C 1 -C 12 alkoxycarboxylic acid” refers to a —O—(C 1 -C 12 alkylene)-COOH radical.
[0118] As used herein the term “alkylene” refers to a saturated, divalent, branched or straight hydrocarbon group having from one to five carbon atoms. Non-limiting examples of C 1-5 -alkylene groups include, methylene, ethylene, 1,2-propylene, 1,3-propylene, butylene, isobutylidene, pentylene, hexylene and the like.
[0119] As used herein the term “ester” is meant to encompass an —COOR group wherein R is an alkyl as defined herein above.
[0120] A used herein the term “ether” refers to an —R′OR group, wherein R′ is a C 1 -C 7 straight or branched alkylene group and R is a C 1 -C 7 straight or branched alkyl group.
[0121] As used herein, the term “alkoxy” refers to an RO— group, where R is alkyl as defined above.
[0122] As used herein the term “C 1 -C 7 amide” refers to a monoalkyl amide (—CONHR) or dialkyl amide (—CONRR′), wherein R and R′ are independently a C 1 -C 7 straight or branched alkyl.
[0123] As used herein the term “C 1 -C 5 amine” refers to an —NHR or —NRR′ group wherein R and R′ are independently a C 1 -C 5 straight or branched alkyl.
[0124] The term “optionally substituted” as used herein means that the groups in question are either unsubstituted or substituted with one or more of the substituents such as for example those specified above and phenyl, substituted phenyl, aryl, heteroaryl, cycloalkyl, heterocycloalkyl, halogen (—F, —Cl, —Br, —I), —COOH, —NH 2 , —NHR and —NRR′ wherein R and R′ are each independently a straight or branched C 1 -C 5 alkyl. When the groups are substituted with more than one substituent the substituents may be the same or different and said substitution may occur at any position on the substituted group (i.e. at a terminal or any mid-chain position or both).
[0125] The term “cycloalkyl” refers to a cyclic ring having from 6 to 12 carbon atoms connected via single bond only.
[0126] The term “cycloalkenyl” refers to a cyclic ring having from 6 to 12 carbon atoms connected having at least one double bond.
[0127] The term “cycloalkynyl” refers to a cyclic ring having from 6 to 12 carbon atoms connected having at least one triple bond.
[0128] The term “cycloheteroalkyl” refers to a cyclic ring having from 6 to 12 carbon atoms connected via single bond only, wherein at least one carbon atom is replaced with a heteroatom selected from N, O, S.
[0129] The term “cycloheteroalkenyl” refers to a cyclic ring having from 6 to 12 carbon atoms connected having at least one double bond, wherein at least one carbon atom is replaced with a heteroatom selected from N, O, S.
[0130] The term “cycloheteroalkynyl” refers to a cyclic ring having from 6 to 12 carbon atoms connected having at least one triple bond, wherein at least one carbon atom is replaced with a heteroatom selected from N, O, S.
[0131] It is appreciated by a person skilled in the art that certain compounds of the invention may posses at least one stereogenic carbon atom. Thus, it should be noted that the present invention encompasses all possible stereosiormers of such compounds including all possible mixtures thereof (such as for example racemic mixtures, diastereomeric mixtures, non-racemic mixtures etc.). It is further noted that compounds of the invention may posses a double bond. Thus, the present invention encompasses any stereoisomer (cis, trans, E or Z stereoisomers) of such compounds including any mixture thereof.
[0132] The invention further provides processes for the preparation of compounds of the invention.
[0133] In one aspect the invention provides a process for the preparation of a compound of general formula (I), as defined herein above, said process comprising:
(a) providing a compound having the general formula (X) or (X′):
[0000]
wherein R a , R b and R c have the same meaning as defined herein above; X is a halide, pseudohalide, functional leaving group (such as for example—OTf and similar functional groups capable of being easily removed upon coupling reaction); and 1 2, 2 3, 3 4 are each independently a single or double bond;
(b) reacting compound (X) or (X′) with a compound having the general formula (XI) or (XI') respectively:
[0000]
wherein each of Y is selected from OH, C 1 -C 5 alkoxy or both may form a cyclic dialkoxy ring together with the boron atom they are attached to, in the presence of a catalyst; thereby obtaining a compound of formula (I).
[0138] In another aspect the invention provides a process for the preparation of a compound of general formula (I), as defined herein above, said process comprising:
(a) providing a compound having the general formula (X) or (X′):
[0000]
wherein R a , R b and R c have the same meaning as defined herein above; X is a halide, pseudohalide, functional leaving group (such as for example—OTf and similar functional groups capable of being easily removed upon coupling reaction); and 1 2, 2 3, 3 4 are each independently a single or double bond;
(b) coupling compound (X) or (X′) with R c —H or R b —H respectively; thereby obtaining a compound of formula (I). In some embodiments said coupling process is a halogen-metal exchange process, as detailed herein below.
[0142] Such processes include for example Suzuki cross-coupling reactions as follows:
1. Methylation of (±) ketopinic acid with methyl iodide and potassium carbonate in dimethylformamide thereby obtaining (±) methyl ketopinate; 2. Enolization of (±) camphor/(±) epicamphor/(±) methyl ketopinate by lithium diisopropylamide and the addition of phenyl triflimide in tetrahydrofuran to afford corresponding (±) vinyl triflate; 3. Lithiation of 2,6-dimethyl ether-4-alkyl resorcinol by n-butyl lithium and formation of aryl boronic ester using isopropyl pinacol borate in tetrahydrofuran; 4. Cross-coupling reaction between aryl boronic ester and (±) vinyl triflate catalyzed by tetrakis-palladium triphenyl phosphine in the presence of tert-butyl ammonium fluoride in tetrahydrofuran to obtain corresponding (±) arylated bornene; 5. Reduction of (±) arylated methyl ketopinate by lithium aluminium hydride in tetrahydrofuran to afford corresponding alcohol; 6. Hydrolisis of (±) arylated methyl ketopinate by lithium hydroxide in methanol/water to obtain corresponding acid.
[0149] Another alternative process for the manufacture of compounds of the invention include halogen-metal exchange process as follows:
1. Lithiation by n-butyl lithium and copper iodide metalation of 2,6-dimethyl ether-4-alkyl resorcinol promoted coupling reaction with (+) 3-bromocamphor in diethyl ether and dimethyl sulfoxide to obtain corresponding arylated camphor 2. Reduction of camphoric carbonyl by lithium aluminium hydride in tetrahydrofuran to afford corresponding alcohol.
[0152] Exemplary synthetic procedures for the manufacture of compounds of the invention are described in Schemes 1 and 2.
[0000]
[0000]
[0153] In a further embodiment a compound of the invention is capable of stimulating a CB receptor.
[0154] The term “CB receptor” is meant to encompass a cannabinoid G-protein coupled receptor, defined by their capability to bind to cannabinoids and/or endocannabinoids. In one embodiment said receptor is a CB2 receptor (cannabinoid receptor Type 2). In another embodiment said stimulation of a CB2 receptor is associated with the treatment of a disease, disorder or condition.
[0155] When referring to “stimulation” of a composition of the invention to a CB receptor it is meant to include any degree of excitation of a CB receptor to allow activation of said receptor, such as for example agonistic effect of a compound of the invention on said CB receptor. It is noted that in order for such a stimulation to be achieved an association between a compound of the invention and said receptor should be established. A compound of the present invention may be associated with said receptor via any type of interaction such as for example covalent bonding, electrostatic bonding (such as for example hydrogen bonding, π or σ interactions, London dispersion forces, Van-Der-Waals forces etc.), ionic bonding, metallic bonding etc.
[0156] CB2 receptor stimulation has been shown to be of considerable medical value (Ashton and Glass, 2007). Some effects relevant to our patent are listed below:
1. Selective CB2 receptor stimulation causes potent anti-inflammatory effects in a diverse range of animal models (Ashton and Glass, 2007; Benito et al. 2008); lowers neuropathic pain (Yamamoto et al., 2008); inhibits secretion of pro-inflammatory cytokines (Klegeris et al., 2003). 2. CB2 receptor agonists stimulate osteoblast function and inhibit osteoclasts leading to increased bone formation. These effects are of major relevance to osteoporosis (Ofek et al., 2005). 3. CB2 receptor stimulation retards progression of atherosclerosis in an animal model (Stefens et al., 2005; Steffens and Mach, 2006). As cerebral hypoxia-ischemia and middle cerebral artery occlusion induce expression of the CB2 receptor, such agonists may lower the effects of these conditions (Ashton et al., 2006). 4. Selective CB2 receptor stimulation has been shown to lower hepatic encephalopathy (a neuropsychiatric complication occurring in both acute and chronic liver failure) and to display anti-fibrinogenic effects (Avraham et al., 2006; Dagon et al., 2007; Lotersztajn et al., 2008). 5. CB2 receptor stimulation has the potential to block progression of Alzheimer's disease (Benito et al., 2008), Huntington's disease (Fernandez-Ruiz et al. 2005), amyotrophic lateral sclerosis (Bilsland et al., 2006; Centonze et al., 2007), multiple sclerosis (Docagne et al., 2008) and myelin disorders (Arevalo-Martin et al., 2008). For a general review see Fernandez-Ruiz et al., (2008). 6. Cannabinoid CB2 receptor activation decreases cerebral infarction in a mouse focal ischemia/reperfusion model and a CB 1 antagonist together with a CB2 agonist improved cerebral blood flow (Zhang et al. 2008). 7. CB2 receptor stimulation helps the establishment of ischemic preconditioning (a potent endogenous form of tissue protection against ischemia-reperfusion in various organs) (Pacher and Hasko, 2008). 8. CB2 receptor stimulation causes inhibition of emesis (van Sickle et al., 2005). 9. CB2 cannabinoid agonists stimulate neural progenitor proliferation (Palazuelos et al., 2006, 2008). This effect may be associated with improvement of neural damage.
[0166] In the context of the present invention the term “treatment” is meant to encompass the management and care of a patient for the purpose of combating a disease, disorder or condition. The term is intended to include the delaying of the progression of a disease, disorder or condition, the alleviation or relief of symptoms and complications, and/or the cure or elimination of the disease, disorder or condition. The patient to be treated is preferably a mammal, in particular a human being. This term refers to the administration of a therapeutic amount of a compound of the invention which is effective in one of the following: ameliorating undesired symptoms associated with a disease, disorder, or pathological condition; effective in preventing the manifestation of such symptoms before they occur; effective in slowing down the progression of a disease or disorder; effective in slowing down the deterioration of a disease, disorder or condition; effective in prolonging the time period onset of remission period; effective in slowing down the irreversible damage caused in a progressive chronic stage of a disorder; effective to delay the onset of said progressive; effective to lessen the severity or cure the disease or disorder; effective to improve survival rates of individuals infected with the disease, or effective to prevent the disease form occurring altogether (for example in an individual generally prone to the disease) or a combination of two or more of the above.
[0167] Thus, in one embodiment of the present invention, said disease, disorder or condition is selected from inflammation, pain, allergies, neurological and neurodegenerative diseases, liver diseases, cerebral injury, cancer, retinal vascularization, endometritis, appetite related disorders, metabolic syndrome, diabetes, atherosclerosis; disorders related to anti-fibrinogenic effects, inflammatory bowel disease, arthritis and emesis, or any combination thereof.
[0168] In a further embodiment, said disease, disorder or condition is cerebral injury. In another embodiment said cerebral injury is brain trauma selected from closed head injury, penetrating head injury, blast injury, cerebral ischemic-reperfusion injury, post-operable brain injury, brain hemorrhaging.
[0169] In another embodiment said compound of the invention is capable of lowering the secondary damage produced by brain trauma.
[0170] The term “cerebral injury”, “brain trauma” or “traumatic brain injury” as used herein interchangeably is meant to encompass any traumatical injury to the brain, which may be caused by an external impac force (such as rapid acceleration or deceleration, impact, blast waves, or penetration by a projectile) or by any disease or disorder (such as for example ischemia, stroke, infection or anyurism).
[0171] Brain trauma can be classified based on severity, mechanism (closed or penetrating head injury), or other features (e.g. occurring in a specific anatomical location or over a widespread area in the brain). Head injuries can also be classified into mild, moderate, and severe categories and may be diagnosed using different International scales measuring for example the level of consciousness of the injured subject.
[0172] In addition to the damage caused at the moment of injury, brain trauma causes secondary injury (secondary damage produced by brain trauma), which is manifested in a variety of events that take place within minutes and/or days following the injury. These processes, which include alterations in cerebral blood flow and the pressure within the skull, contribute substantially to the damage from the initial injury. As a result brain function may be temporarily or permanently impaired and structural damage may or may not be detectable.
[0173] Deterioration in brain function and neurological functions of the brain can be attributed not only to the primary brain injury (the damage that occurs at the moment of trauma when tissues and blood vessels are stretched, compressed, and torn) but rather, to the secondary injury, expressed by a complex set of cellular processes and biochemical cascades that occur in the minutes to days following the trauma. These secondary processes can dramatically worsen the damage caused by primary injury and account for the greatest number of permannet imparment and also deaths. Secondary events include but are not limited to damage to the blood—brain barrier, release of factors that cause inflammation, free radical overload, excessive release of the neurotransmitter glutamate (excitotoxicity), influx of calcium and sodium ions into neurons, and dysfunction of mitochondria. Injured axons in the brain's white matter may separate from their cell bodies as a result of secondary injury, potentially killing those neurons. Other factors in secondary injury are changes in the blood flow to the brain; ischemia (insufficient blood flow); cerebral hypoxia (insufficient oxygen in the brain); cerebral edema (swelling of the brain); and raised intracranial pressure (the pressure within the skull). Intracranial pressure may rise due to swelling or a mass effect from a lesion, such as a hemorrhage. As a result, cerebral perfusion pressure (the pressure of blood flow in the brain) is reduced; ischemia results. When the pressure within the skull is too high, it can cause brain death or herniation, in which parts of the brain are squeezed by structures in the skull.
[0174] In another embodiment, a compound of the invention is utilized for use as a medicament.
[0175] In a further embodiment, a compound of the invention is used in the treatment of disease, disorder or condition is selected from inflammation, pain, allergies, neurological and neurodegenerative diseases, liver diseases, cerebral injury, cancer, retinal vascularization, endometritis, appetite related disorders, metabolic syndrome, diabetes, atherosclerosis; disorders related to anti-fibrinogenic effects, inflammatory bowel disease, arthritis and emesis, or any combination thereof. In one embodiment, a compound of the invention is used in the treatment of cerebral injury. In one embodiment said cerebral injury is selected from closed head injury, penetrating head injury, blast injury, cerebral ischemic-reperfusion injury, post-operable brain injury, brain hemorrhaging. In another embodiment a compound of the invention is utilized for use in lowering secondary damage produced by brain trauma.
[0176] In another one of its aspects the invention provides a pharmaceutical composition comprising a compound of the invention.
[0177] In one embodiment said pharmaceutical composition of the invention is for use in the treatment of disease, disorder or condition is selected from inflammation, pain, allergies, neurological and neurodegenerative diseases, liver diseases, cerebral injury, cancer, retinal vascularization, endometritis, appetite related disorders, metabolic syndrome, diabetes, atherosclerosis; disorders related to anti-fibrinogenic effects, inflammatory bowel disease, arthritis and emesis, or any combination thereof. In another embodiment said disease, disorder or condition is cerebral injury. In a further embodiment said cerebral injury is selected from closed head injury, penetrating head injury, blast injury, cerebral ischemic-reperfusion injury, post-operable brain injury, brain hemorrhaging. In another embodiment a pharmaceutical composition of the invention is used in lowering secondary damage produced by brain trauma.
[0178] In a further aspect of the invention, there is provided a use of a compound of the invention, for the manufacture of a pharmaceutical composition.
[0179] In some embodiments said p pharmaceutical composition is for use in the stimulation of bone growth, bone mass, bone repair or prevention of bone loss.
[0180] In another aspect, the invention provides a use of a compound of the invention, for the manufacture of a medicament (or pharmaceutical composition) capable of stimulating a CB receptor. In one embodiment receptor is a CB2 receptor.
[0181] In a further aspect the invention provides a use of a compound of the invention, for the manufacture of a medicament for the treatment of cerebral injury.
[0182] In another aspect the invention provides a use of a compound of the invention, for the manufacture of a medicament for lowering secondary damage produced by brain trauma.
[0183] In another one of its aspects the invention provides a use of a compound of the invention, for the preparation of a pharmaceutical composition for stimulation of bone growth, bone mass, bone repair or prevention of bone loss.
[0184] In a further aspect of the invention there is provided a compound of the invention, for use in the stimulation of bone growth, bone mass, bone repair or prevention of bone loss.
[0185] In another one of its aspects the invention provides a method of stimulation of bone growth, bone mass, bone repair or prevention of bone loss, said method comprising administering to a subject in need thereof a therapeutically effective amount of at least one compound of the invention.
[0186] In some embodiments said stimulation of bone growth, bone mass, bone repair or prevention of bone loss is associated with the treatment of at least one disease or a disorder selected from osteopenia, osteoporosis, bone fracture or deficiency, primary or secondary hyperparathyroidism, osteoarthritis, periodontal disease or defect, an osteolytic bone loss disease, post-plastic surgery, post-orthopedic surgery, post oral surgery, post-orthopedic implantation, and post-dental implantation, primary and metastatic bone cancer, osteomyelitis, or any combinations thereof.
[0187] In other embodiments said at least one disease or disorder is selected from osteopenia and osteoporosis.
[0188] The term “stimulation of bone growth, bone mass, bone repair” is meant to encompass any quantitative and/or qualitative promotion of growth of the osseous tissue, any quantitative and/or qualitative promotion of mass of the osseous tissue and any quantitative and/or qualitative promotion of osseous tissue repair (for example in the case any part of the osseous tissue is damaged or fractured for example after impact or as a consequence of a disease, condition or any side effect of an external treatment) in vertebrates at any development stage (from embryonic stage to elderly). In some embodiments, the pharmaceutical composition is for increasing bone mass in a subject in need thereof. In other embodiments, the pharmaceutical composition is for promoting bone repair.
[0189] The term “prevention of bone loss” is meant to encompass any quantitative and/or qualitative deterrence of osseous tissue loss in vertebrates at any development stage (from embryonic development stage to elderly).
[0190] Non-limiting examples of medical conditions benefiting from stimulating bone growth, gain of bone mass, prevention and rescue of bone loss and bone repair are osteopenia, osteoporosis, bone fracture or deficiency, primary or secondary hyperparathyroidism, osteoarthritis, periodontal disease or defect, an osteolytic bone loss disease, post-plastic surgery, post-orthopedic surgery, post oral surgery, post-orthopedic implantation, and post-dental implantation, primary and metastatic bone cancer, osteomyelitis, or any combinations thereof. In some embodiments, a medical condition benefiting from stimulating bone growth is osteopenia or osteoporosis.
[0191] When referring to pharmaceutical compositions comprising a compound of the subject invention it should be understood to encompass admixtures of compounds of the invention, with pharmaceutically acceptable auxiliaries, and optionally other therapeutic agents. The auxiliaries must be “acceptable” in the sense of being compatible with the other ingredients of the composition and not deleterious to the recipients thereof.
[0192] Pharmaceutical compositions include those suitable for oral, rectal, nasal, topical (including transdermal, buccal and sublingual), vaginal or parenteral (including subcutaneous, intramuscular, intravenous and intradermal) administration or administration via an implant. The compositions may be prepared by any method well known in the art of pharmacy. Such methods include the step of bringing in association compounds used in the invention or combinations thereof with any auxiliary agent.
[0193] Auxiliary agent(s), also named accessory ingredient(s), include those conventional in the art, such as carriers, fillers, binders, diluents, disintegrants, lubricants, colorants, flavouring agents, anti-oxidants, and wetting agents.
[0194] Pharmaceutical compositions suitable for oral administration may be presented as discrete dosage units such as pills, tablets, dragées or capsules, or as a powder or granules, or as a solution or suspension. The active ingredient may also be presented as a bolus or paste. The compositions can further be processed into a suppository or enema for rectal administration.
[0195] The invention further includes a pharmaceutical composition, as hereinbefore described, in combination with packaging material, including instructions for the use of the composition for a use as hereinbefore described.
[0196] For parenteral administration, suitable compositions include aqueous and non-aqueous sterile injection. The compositions may be presented in unit-dose or multi-dose containers, for example sealed vials and ampoules, and may be stored in a freeze-dried (lyophilised) condition requiring only the addition of sterile liquid carrier, for example water, prior to use.
[0197] For transdermal administration, e.g. gels, patches or sprays can be contemplated. Compositions or formulations suitable for pulmonary administration e.g. by nasal inhalation include fine dusts or mists which may be generated by means of metered dose pressurized aerosols, nebulisers or insufflators.
[0198] The exact dose and regimen of administration of the composition will necessarily be dependent upon the therapeutic or nutritional effect to be achieved and may vary with the particular formula, the route of administration, and the age and condition of the individual subject to whom the composition is to be administered.
[0199] In a further aspect the invention provides a method for stimulating a CB receptor in a subject in need thereof, said method comprising administering to said subject a therapeutically effective amount of a compound of the invention. In one embodiment said CB receptor is a CB2 receptor.
[0200] In another one of its aspects the invention provides a method of treating a disease, disorder or condition is selected from inflammation, pain, allergies, neurological and neurodegenerative diseases, liver diseases, cerebral injury, cancer, retinal vascularization, endometritis, appetite related disorders, metabolic syndrome, diabetes, atherosclerosis; disorders related to anti-fibrinogenic effects, inflammatory bowel disease, arthritis and emesis, or any combination thereof, said method comprising administering to in a subject in need thereof an effective amount of a compound of the invention.
[0201] In a further aspect the invention provides a method of treating cerebral injury in a subject in need thereof, said method comprising administering to said subject an effective amount of a compound of the invention. In one embodiment said cerebral injury is selected from closed head injury, penetrating head injury, blast injury, cerebral ischemic-reperfusion injury, post-operable brain injury, brain hemorrhaging.
[0202] In a further aspect the invention provides a method of lowering secondary damage produced by brain trauma in a subject in need thereof, said method comprising administering to said subject an effective amount of a compound of the invention.
[0203] In a further aspect the invention provides a method of affecting the c-AMP formation in a subject in need thereof, said method comprising administering to said subject an effective amount of a compound of the invention.
[0204] When referring to the influence of a compound of the invention on the “affecting the c-AMP formation” it should be understood to encompass stimulation or inhibition of forskolin-induced c-AMP accumulation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0205] In order to understand the invention and to see how it may be carried out in practice, embodiments will now be described, by way of non-limiting example only, with reference to the accompanying drawings, in which:
[0206] FIG. 1 A-1G show the GTγS binding graphs for human CB2 receptor of compounds of the invention: HU-308 ( FIG. 1A ), HU-909 ( FIG. 1B ), HU-910 ( FIG. 1C ), HU-911 ( FIG. 1D ), HU-913 ( FIG. 1E ), HU-926 ( FIG. 1F ) and HU-928 ( FIG. 1G ). Data is shown as [ 35 S]GTPγS binding normalised to maximal HU-308 binding under the same experimental conditions.
[0207] FIG. 2 shows the extent of recovery (measured as ΔNSS (Neurological Severity Score)=NSS(1 h)—NSS(t)) in a period of between 24 h to 21 days post closed head trauma (CHI) for groups receiving different doses of HU-910 (14b), (c1=0.1 mg/kg, c2=1 mg/kg, c3=10 mg/kg, injected i.p. 1 h after CHI). Control group (veh) received the vehicle alone (ethanol:cremophor:saline at ratio of 1:1:18).
[0208] FIG. 3 shows the extent of recovery (measured as ΔNSS (Neurological Severity Score)=NSS(1 h)—NSS(t)) in a period of between 24 h to 14 day post closed head trauma (CHI) for groups receiving: 10 mg/kg of HU-910 (14b) (injected i.p. 1 h after CHI), 1 mg/kg SR144528 CB2 antagonist alone, 1 mg/kg SR144528 CB2 antagonist and 10 mg/kg of HU-910 after 10 min. Control group (veh) received the vehicle alone (ethanol:cremophor:saline at ratio of 1:1:18).
[0209] FIG. 4 depicts the recovery of the four groups measured as ΔNSS (measured as ΔNSS (Neurological Severity Score)=NSS(1 h)—NSS(t)), for a period of 1 h to 28 days post CHI.
[0210] FIG. 5 depicts the Neurological Severity Score (ΔNSS=NSS(1 h)—NSS(t)) was followed during 24 h to 21 days post CHI.
[0211] FIG. 6 depicts the extent of recovery of the four groups (measured as ΔNSS=NSS(1 h)—NSS(t), for a period of 24 h to 28 day post CHI).
[0212] FIG. 7 depicts the Neurological Severity Score (NSS) as followed during 1 h to 14 days post CHI.
[0213] FIGS. 8A-8D depicts TNF-α production following CHI in left Cortex ( FIG. 8A ), left hippocampus ( FIG. 8B ), right Cortex ( FIG. 8C ) and right Hyppocampus ( FIG. 8D ).
DETAILED DESCRIPTION OF EMBODIMENTS
[0214] The following Examples are representative of techniques employed by the inventors in carrying out aspects of the present invention. It should be appreciated that while these techniques are exemplary of preferred embodiments for the practice of the invention, those of skill in the art, in light of the present disclosure, will recognize that numerous modifications can be made without departing from the spirit and intended scope of the invention.
EXAMPLE 1
Synthetic Preparations
[0215] Materials and Methods
[0216] All reagents were purchased from Sigma-Aldrich (Israel) and Acros (Israel) and used without further purification. (±)-Camphor and (+)-3-bromocamphor were purchased from Sigma-Aldrich (Israel). (±)-Camphor-10-sulfonyl chloride and (±)-camphorquinone were purchased from Acros (Israel).
[0217] All solvents were purchased from Bio-Lab (Israel).
[0218] All anhydrous reactions were performed under nitrogen atmosphere in flame-dried glassware using anhydrous solvents.
[0219] Silica gel 60 Å 0.063-0.2 mesh was purchased from BioLab (Israel) and used for column chromatography.
[0220] Preparative thin layer chromatography (TLC) was performed on PLC silica gel plates 60 Å F 254 , 2 mm, purchased form Merck (Germany).
[0221] Purity of the intermediates and final compounds was established by analytical TLC on precoated aluminum silica gel 60, F 254 , 200 μm, purchased from Merck (Germany) and chromatograms were visualized under ultraviolet light and by phosphomolybdic acid staining.
[0222] Melting points were determined on a capillary electrothermal melting point apparatus and are uncorrected.
[0223] 1 H NMR spectra were recorded on Varian Unity Inova 300 MHz spectrometer and processed with the MestReC software. All NMR spectra were recorded using CDCl 3 as solvent unless otherwise stated and chemical shifts are reported in ppm relative to tetramethylsilane as internal standard. Multiplicities are indicated as s (singlet), d (doublet), dd (doblet of doublets), ddd (doublet of doublet of doublets), dddd (doublet of doublet of doublet of doublets), t (triplet), m (multiplet), and coupling constants (J) are reported in hertz (Hz).
[0224] Mass spectra were recorded on a Hewlett-Packard G2000 GC/MS system with HP-5971 gas chromatograph with an electron ionization detector.
[0225] Elemental analyses were performed on Perkin-Elmer 2400 series II Analyzer by Microanalytical Laboratory at the Department of Chemistry, Hebrew University of Jerusalem.
[0226] Synthetic Preparations of Compounds (3) and (4):
[0000]
[0227] 2-(2,6-dimethoxy-4-(2-methylheptan-2-yl)phenyl)-4,4,5,5-tetramethyl-1,3,2-dioxaborolane. (3). To a solution of 4-alkyl resorcinol dimethylether 1 0.132 g (0.5 mmol) in 4 ml of THF n-BuLi 0.34 ml (0.55 mmol, 1.6 M solution in hexane) was added at 0° C. After additional stirring for 1 h at 0° C., the reaction mixture was cooled to −78° C. and a solution of PINBOP 0.15 ml (0.75 mmol) was added all at once. The reaction mixture was allowed to warm up to the room temperature and continued to stir overnight. The reaction worked up with aqueous NH 4 Cl, extracted with 3 portions of diethyl ether which washed with brine and water. The organic phase was dried over MgSO 4 and concentrated in vacuo. The product was obtained as a non-separable mixture of pinacol aryl boronate 3 and 4-alkyl resorcinol dimethylether 1 (in ratio 4:3 according to GC-MS analysis) 0.19 g and was used as it is in Suzuki coupling reaction. The 1 H NMR (300 MHz, CDCl 3 ) δ ppm 6.41 (s, 2H), 3.76 (s, 6H), 1.51-1.58 (m, 2H), 1.37 (s, 6H), 1.25 (s, 6H), 1.24 (s, 6H), 1.13-1.21 (m, 8H), 0.84 (t, J=6.87 Hz, 3H). Exact mass calculated for C 27 H 34 O 3 m/e 390.29; found 390.80.
[0228] 2-(2,6-dimethoxy-4-pentylphenyl)-4,4,5,5-tetramethyl-1,3,2-dioxaborolane (4). The title compound was prepared by the general procedure described for compound 3, using 4-alkyl resorcinol dimethylether 2 0.104 g (0.5 mmol) in 4 ml of THF, n-BuLi 0.34 ml (0.55 mmol, 1.6 M solution in hexane) and PINBOP 0.15 ml (0.75 mmol). The product was obtained as a non-separable mixture 0.165 g of pinacol aryl boronate 4 and 4-alkyl resorcinol dimethylether 2 (in ratio 4:3 according to GC-MS analysis) and was used as it is in Suzuki coupling reaction. 1 H NMR (300 MHz, CDCl 3 ) δ ppm 6.28 (s, 2H), 3.76 (s, 6H), 2.55 (t, J=7.53 Hz, 2H), 1.55-1.63 (m, 2H), 1.27 (s, 6H), 1.26 (s, 6H), 1.24 (m, 4H), 0.87 (m, 3H). Exact mass calculated for C 27 H 34 O 3 m/e 334.23; found 334.62.
[0229] Synthetic Preparations of Compound (7):
[0000]
[0230] (1R,4S)-methyl-7,7-dimethyl-2-oxobicyclo[2.2.1]heptane-1-carboxylate (7a) To a mixture of ketopinic acid 6a 0.182 g (1 mmol) and K 2 CO 3 1.1 g (8 mmol) stirred in DMF 10 ml was added MeI 0.125 ml (0.284 g, 2 mmol). The reaction mixture was allowed to stir for 18 hrs at ambient temperature. The reaction mixture was dissolved in water 80 ml and extracted with 3×30 ml portions of diethyl ether. The organic phase was washed with NaHCO 3 saturated solution, dried over MgSO 4 and concentrated in vacuo to give yellow oil 0.184 g (94%). 1 H NMR (300 MHz, CDCl 3 ) δ ppm 3.75 (s, 3H), 2.53 (ddd, J=18.29, 3.7 Hz, 1H), 2.36 (ddd, J=14.99, 11.82, 3.99 Hz, 1H), 2.10 (t, J=4.4 Hz, 1H), 2.02 (m, 1H), 1.92-1.98 (d, J=18.40 Hz, 1H), 1.79 (ddd, J=14.16, 9.35, 4.95 Hz, 1H), 1.41 (ddd, J=12.65, 9.49, 4.26 Hz, 1H), 1.15 (s, 3H), 1.07 (s, 3H). Exact mass calculated for C 11 H 16 O 3 m/e 196.11; found 196.22.
[0231] (1S,4R)-methyl-7,7-dimethyl-2-oxobicyclo[2.2.1]heptane-1-carboxylate (7b) The title compound was prepared from 6b by the general procedure described for compound 7a. Yellow oil (96%). 1 H NMR (300 MHz, CDCl 3 ) δ ppm 3.75 (s, 3H), 2.53 (ddd, J=18.29, 3.7 Hz, 1H), 2.36 (ddd, J=14.99, 11.82, 3.99 Hz, 1H), 2.10 (t, J=4.4 Hz, 1H), 2.02 (m, 1H), 1.92-1.98 (d, J=18.40 Hz, 1H), 1.79 (ddd, J=14.16, 9.35, 4.95 Hz, 1H), 1.41 (ddd, J=12.65, 9.49, 4.26 Hz, 1H), 1.15 (s, 3H), 1.07 (s, 3H). Exact mass calculated for C 11 H 16 O 3 m/e 196.11; found 196.22.
[0232] Synthetic Preparations of Compounds (9) and (10):
[0000]
[0233] (1R,4S)-methyl-7,7-dimethyl-2-(trifluoromethylsulfonyloxy)bicyclo[2.2.1]hept-2-ene-1-carboxylate (9a) Precooled (0° C.) solution of methyl ester 7a 0.06 g (0.3 mmol) in 1.5 ml THF was added to a solution of LDA 0.17 ml (0.34 mmol, 2M solution) in 2 ml THF at −78° C. and resultant solution was allowed to stir for 2 hrs. A solution of phenyl triflimide 0.115 g (0.32 mmol) in 2 ml of THF was added, and the reaction was stirred at 0° C. for 3 hrs and was allowed to stir for additional 15 hrs at room temperature. After the solvent removal at the rotary evaporator, the resultant, yellow oil was purified by silica gel chromatography (petroleum ether/ether) to give brownish oil 0.07 g (71%). 1 H NMR (300 MHz, CDCl 3 ) δ ppm 5.81 (d, J=3.74, 1H), 3.77 (s, 3H), 2.51 (t, J=3.67 Hz, 1H), 2.39 (ddd, J=3.71, 8.76, 12.47 Hz, 1H), 2.03-2.13 (m, 1H), 1.65 (ddd, J=3.68, 9.18, 12.65 Hz, 1H), 1.24 (ddd, J=3.72, 9.18, 12.64 Hz, 1H), 1.11(s, 3H), 0.97 (s, 3H). Exact mass calculated for C 12 H 15 F 3 O 5 S m/e 328.06; found 328.44.
[0234] (1 S,4R)-methyl-7,7-dimethyl-2-(trifluoromethylsulfonyloxy)bicyclo[2.2.1] hept-2-ene-1-carboxylate (9b) The title compound was prepared from 7b by the general procedure described for compound 9a. Brownish oil (68%). 1 H NMR (300 MHz, CDCl 3 ) δ ppm 5.81 (d, J=3.74, 1H), 3.77 (s, 3H), 2.51 (dd, J=3.67, 3.67 Hz, 1H), 2.39 (ddd, J=3.71, 8.76, 12.47 Hz, 1H), 2.03-2.13 (m, 1H), 1.65 (ddd, J=3.68, 9.18, 12.65 Hz, 1H), 1.24 (ddd, J=3.72, 9.18, 12.64 Hz, 1H), 1.11(s, 3H), 0.97 (s, 3H). Exact mass calculated for C 12 H 15 F 3 O 5 S m/e 328.06; found 328.44.
[0235] Synthetic Preparations of Compounds (11), (12) and (13):
[0000]
[0236] (1R,4S)-methyl-2-(2,6-dimethoxy-4-(2-methyloctan-2-yl)phenyl)-7,7-dimethylbicyclo[2.2.1]hept-2-ene-1-carboxylate (11a) A pinacol arylboronate 3 (mixed with 4-alkyl resorcinol dimethylether 1) 0.474 g, enol triflate 9a 0.328 g (1.00 mmol), Pd(PPh 3 ) 4 0.07 g (0.006 mmol) and t-BuNF 1.5 ml (1.5 mmol, 1M solution in THF) in THF 15 ml were refluxed for 15 hrs. The reaction mixture was filtered through Celite and the filtrate was concentrated in vacuo. Further purification by silica gel column chromatography (petroleum ether/ether) afforded a desired product as pale yellow oil 0.288 g (65%). 1 H NMR (300 MHz, CDCl 3 ) δ ppm 6.45 (s, 2H), 6.28 (d, J=3.42 Hz, 1H), 3.72 (s, 6H), 3.45 (s, 3H), 2.43 (m, 2H), 1.80-2.03 (m, 1H), 1.53-1.58 (m, 2H), 1.26 (s, 6H), 1.13-1.22 (m, 7H), 1.11 (s, 3H), 0.98-1.08 (m, 3H), 0.97 (s, 3H), 0.84 (t, J=6.79 Hz, 3H). Exact mass calculated for C 28 H 42 O 4 m/e 442.31; found 442.92. Anal. calcd. for C 28 1 - 1 42 0 4 : C, 75.98; H, 9.56. Found: C, 76.14; H, 9.65.
[0237] (1 S,4R)-methyl-2-(2,6-dimethoxy-4-(2-methyloctan-2-yl)phenyl)-7,7-dimethylbicyclo[2.2.1]hept-2-ene-1-carboxylate (11b, HU-912) The title compound was prepared from 9b by the general procedure described for compound 11a. Yellowish oil (69%). 1 H NMR (300 MHz, CDCl 3 ) δ ppm 6.45 (s, 2H), 6.28 (d, J=3.42 Hz, 1H), 3.72 (s, 6H), 3.45 (s, 3H), 2.43 (m, 2H), 1.80-2.03 (m, 1H), 1.53-1.58 (m, 2H), 1.26 (s, 6H), 1.13-1.22 (m, 7H), 1.11 (s, 3H), 0.98-1.08 (m, 3H), 0.97 (s, 3H), 0.84 (t, J=6.79 Hz, 3H). Exact mass calculated for C 28 H 42 O 4 m/e 442.31; found 442.91. Anal. calcd. for C 28 H 42 O 4 : C, 75.98; H, 9.56. Found: C, 75.58; H, 9.70.
[0238] (1R,4S)-methyl-2-(2,6-dimethoxy-4-pentylphenyl)-7,7-dimethylbicyclo[2.2.1]hept-2-ene-1-carboxylate (13a, HU-971) The title compound was prepared by the general procedure described for compound 11a (HU-911), using pinacol arylboronate 4 (mixed with 2) 0.244 g, enol triflate 9a 0.2 g (0.61 mmol), Pd(PPh 3 ) 4 0.042 g (0.037 mmol) and t-BuNF 0.91 ml (0.91 mmol, 1M solution in THF) to give colorless oil 170 mg (72%). 1 H NMR (300 MHz, CDCl 3 ) δ ppm 6.33 (s, 2H), 6.26 (d, J=3.42 Hz, 1H), 3.71 (s, 6H), 3.47 (s, 3H), 2.55 (t, J=7.70 Hz, 2H), 2.38-2.46 (m, 2H), 1.81-2.03 (m, 2H), 1.56-1.66 (m, 2H), 1.30-1.35 (m, 4H), 1.12 (s, 3H, syn), 1.07-1.16 (m, 1H), 0.97 (s, 3H, anti), 0.90 (t, J=6.84 Hz, 3H). Exact mass calculated for C 24 H 34 O 4 by the general procedure described for compo 4 O 4 : C, 74.58; H, 8.87. Found : C, 74.61; H, 9.04.
[0239] (1 S,4R)-methyl-2-(2,6-dimethoxy-4-pentylphenyl)-7,7-dimethylbicyclo[2.2.1]hept-2-ene-1-carboxylate (13b, HU-972). The title compound was prepared from 9b by the general procedure described for compound 13a (HU-971). Colorless oil (69%). 1 H NMR (300 MHz, CDCl 3 ) δ ppm 6.33 (s, 2H), 6.26 (d, J=3.42 Hz, 1H), 3.71 (s, 6H), 3.47 (s, 3H), 2.55 (t, J=7.70 Hz, 2H), 2.38-2.46 (m, 2H), 1.81-2.03 (m, 2H), 1.56-1.66 (m, 2H), 1.30-1.35 (m, 4H), 1.12 (s, 3H, syn), 1.07-1.16 (m, 1H), 0.97 (s, 3H, anti), 0.90 (t, J=6.84 Hz, 3H). Exact mass calculated for C 24 H 34 O 4 m/e 386.25; found 386.67. Anal. calcd. for C 24 H 34 O 4 : C, 74.58; H, 8.87. Found: C, 74.31; H, 8.90.
[0240] (1R,4R)-2-(2,6-dimethoxy-4-(2-methyloctan-2-yl)phenyl)-1,7,7-trimethylbicyclo[2.2.1]hept-2-ene (12a, HU-907). The title compound was prepared by the general procedure described for compound 11a, using pinacol arylboronate 3 (mixed with 1) 0.755 g, camphor enol triflate 10a 0.5 g (1.76 mmol), Pd(PPh 3 ) 4 0.122 g (0.011 mmol) and t-BuNF 2.64 ml (2.64 mmol, 1M solution in THF) to give yellowish oil 0.525 g (75%), which solidified upon standing at −20° C. to give a white solid. mp 34-36° C.; 1 H NMR (300 MHz, CDCl 3 ) δ ppm 6.50 (s, 2H), 5.87 (d, J=3.27 Hz, 1H), 3.74 (s, 6H), 2.37 (t, J=3.46, 1H), 1.88 (m, 1H), 1.65 (m, 1H), 1.61 (m, 2H), 1.55 (m, 1H), 1.30 (s, 6H), 1.15 (m, 1H), 1.19-1.26 (m, 6H), 1.07-1.18 (m, 2H), 1.05 (s, 3H), 0.86 (t, J=6.71 Hz, 3H), 0.83 (s, 3H), 0.82 (s, 3H). Exact mass calculated for C 27 H 42 O 2 m/e 398.32; found 398.79. Anal. calcd. for C 27 H 42 O 2 : C, 81.35; H, 10.62. Found: C, 81.08; H, 10.69.
[0241] (1 S,4S)-2-(2,6-dimethoxy-4-(2-methyloctan-2-yl)phenyl)-1,7,7-trimethylbicyclo[2.2.1]hept-2-ene (12b, HU-908). The title compound was prepared from 10b by the general procedure described for compound 12a (HU-907). White solid (81%). mp 35-37° C.; 1 H NMR (300 MHz, CDCl 3 ) δ ppm 6.50 (s, 2H), 5.87 (d, J=3.27 Hz, 1H), 3.74 (s, 6H), 2.37 (t, J=3.46, 1H), 1.88 (m, 1H), 1.65 (m, 1H), 1.61 (m, 2H), 1.55 (m, 1H), 1.30 (s, 6H), 1.15 (m, 1H), 1.19-1.26 (m, 6H), 1.07-1.18 (m, 2H), 1.05 (s, 3H), 0.86 (t, J=6.71 Hz, 3H), 0.83 (s, 3H), 0.82 (s, 3H). Exact mass calculated for C 27 14 42 0 2 m/e 398.32; found 398.79. Anal. calcd. for C 27 H 42 O 2 : C, 81.35; H, 10.62. Found: C, 81.47; H, 10.85.
[0242] Synthetic Preparations of Compounds (14) and (15):
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[0243] (1R,4S)-(2-(2,6-dimethoxy-4-(2-methyloctan-2-yl)phenyl)-7,7-dimethylbicyclo[2.2.1]hept-2-en-1-yl)methanol (14a, HU-909). Solution of methyl ester 11a 0.790 g (1.79 mmol) in THF 20 ml was cooled to 0° C. After addition of LiAlH 4 3.58 ml (3.58 mmol, 1M solution in diethyl ether) the reaction was allowed to warm up to ambient temperature and stirred for 18 hrs. The reaction worked up with a small amount of saturated MgSO 4 solution and extracted with ethyl acetate. The organic phase was washed with brine and water, dried over MgSO 4 and concentrated in vacuo. The product was purified by silica gel column chromatography (petroleum ether/ether) to give oil 0.460 g (62%), which solidified upon standing at −20° C. to give a yellow solid. mp 49-51° C.; 1 H NMR (300 MHz, CDCl 3 ) δ ppm 6.52 (s, 2H), 5.90 (d, J=3.24 Hz, 1H), 3.75 (s, 6H), 3.65 (m, 2H), 2.35 (t, J=3.39, 1H), 2.25 (dd, J=7.29, J=5.01,1H), 1.93 (m, 1H), 1.53-1.59 (m, 5H), 1.27 (s, 6H), 1.21 (s, 3H), 1.0-1.19 (m, 7H), 0.94 (s, 3H), 0.85 (t, J=6.71 Hz, 3H). Exact mass calculated for C 27 14 42 0 3 m/e 414.31; found 414.87. Anal. calcd. for C 27 H 42 O 3 : C, 78.21; H, 10.21. Found: C, 78.31; H, 10.31.
[0244] (1 S,4R)-(2-(2,6-dimethoxy-4-(2-methyloctan-2-yl)phenyl)-7,7-dimethylbicyclo[2.2.1]hept-2-en-1-yl)methanol (14b, HU-910). The title compound was prepared from 11b (HU-912) by the general procedure described for compound 14a (HU-909). White solid (64%). mp 48-50° C.; 1 H NMR (300 MHz, CDCl 3 ) δ ppm 6.52 (s, 2H), 5.90 (d, J=3.24 Hz, 1H), 3.75 (s, 6H), 3.65 (m, 2H), 2.35 (t, J=3.39, 1H), 2.25 (dd, J=7.29, J=5.01,1H), 1.93 (m, 1H), 1.53-1.59 (m, 5H), 1.27 (s, 6H), 1.21 (s, 3H), 1.0-1.19 (m, 7H), 0.94 (s, 3H), 0.85 (t, J=6.71 Hz, 3H). Exact mass calculated for C 27 H 42 O 3 m/e 414.31; found 414.86. Anal. calcd. for C 27 14 42 0 3 : C, 78.21; H, 10.21. Found: C, 78.08; H, 10.32.
[0245] (1R,4S)-(2-(2,6-dimethoxy-4-pentylphenyl)-7,7-dimethylbicyclo[2.2.1] hept-2-en-1-yl)methanol (15a, HU-969). The title compound was prepared by the general procedure described for compound 14a (HU-909), using methyl ester 13a (HU-971) 0.1 g (0.259 mmol) in 3 ml of dry THF and LiAlH 4 0.51 ml (0.518 mmol, 1M solution in diethyl ether). The product was purified by silica gel column chromatography (petroleum ether/ether) to give oil 0.086 g (93%), which solidified upon standing at −20° C. to give a white solid. mp 28-29° C.; 1 H NMR (300 MHz, CDCl 3 ) δ ppm 6.40 (s, 2H), 5.88 (d, J=3.24 Hz, 1H), 3.74 (s, 6H), 3.65 (d, J=2.51 Hz, 2H), 2.58 (t, J=7.70 Hz, 2H), 2.35 (t, J=3.41 Hz, 1H), 1.89-1.98 (m, 1H), 1.54-1.66 (m, 4H), 1.32-1.38 (m, 4H), 1.23 (s, 3H), 1.11-1.19 (m, 1H), 0.94 (s, 3H), 0.92 (t, J=6.84 Hz, 3H). Exact mass calculated for C 23 H 34 O 3 m/e 358.25; found 358.67. Anal. calcd. for C 23 H 34 0 3 : C, 77.05; H, 9.56. Found: C, 77.06; H, 9.72.
[0246] (1 S,4R)-(2-(2,6-dimethoxy-4-pentylphenyl)-7,7-dimethylbicyclo[2.2.1] hept-2-en-1-yl)methanol (15b, HU-970). The title compound was prepared from 10b by the general procedure described for compound 13b (HU-972). Oil (83%), which solidified upon standing at -20° C. mp 26-27° C; 1 H NMR (300 MHz, CDCl 3 ) δ ppm 6.40 (s, 2H), 5.88 (d, J=3.24 Hz, 1H), 3.74 (s, 6H), 3.65 (d, J=2.51 Hz, 2H), 2.58 (t, J=7.70 Hz, 2H), 2.35 (t, J=3.41 Hz, 1H), 1.89-1.98 (m, 1H), 1.54-1.66 (m, 4H), 1.32-1.38 (m, 4H), 1.23 (s, 3H), 1.11-1.19 (m, 1H), 0.94 (s, 3H), 0.92 (t, J=6.84 Hz, 3H). Exact mass calculated for C 23 H 34 0 3 m/e 358.25; found 358.71. Anal. calcd. for C 23 H 34 O 3 : C, 77.05; H, 9.56. Found: C, 76.25; H, 9.55.
[0247] Synthetic Preparations of Compounds (16) and (17):
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[0248] (1R,4S)-2-(2,6-dimethoxy-4-(2-methyloctan-2-yl)phenyl)-7,7-dimethylbicyclo[2.2.1]hept-2-ene-1-carboxylic acid (16a, HU-913). Methyl ester 11a (HU-911) 0.103 g (0.233 mmol) and LiOH 0.111 g (4.66 mmol) in 2 ml of MeOH/H 2 O 3:1 were heated at 200° C. over 48 hrs in a screwed vial under air atmosphere. Water was added to the reaction mixture and extracted several times with ether. Organic phases were collected, dried over MgSO 4 and concentrated in vacuo. The product was purified by preparative TLC (hexane/ethyl acetate) to give yellow solid 0.026 g (26%). mp 101-102° C.; 1 H NMR (300 MHz, CDCl 3 ) δ ppm 6.46 (s, 2H), 6.32 (d, J=3.40 Hz, 1H), 3.71 (s, 6H), 2.46 (t, J=3.44 Hz, 1H), 2.38-2.44 (m, 1H), 1.80-2.03 (m, 1H), 1.53-1.58 (m, 2H), 1.26 (s, 6H), 1.16-1.24 (m, 7H), 1.14 (s, 3H), 1.03-1.12 (m, 3H), 1.00 (s, 3H), 0.85 (t, J=6.74 Hz, 3H). Exact mass calculated for C 28 14 42 0 4 m/e 428.29; found 428.98. Anal. calcd. for C 28 H 42 O 4 : C, 75.66; H, 9.41. Found: C, 75.50; H, 9.48.
[0249] (1 S,4R)-2-(2,6-dimethoxy-4-(2-methyloctan-2-yl)phenyl)-7,7-dimethylbicyclo[2.2.1]hept-2-ene-1-carboxylic acid (16b, HU-914). The title compound was prepared from 11b (HU-912) by the general procedure described for compound 16a (HU-913). Yellow solid (25%). mp 100-101° C.; 1 H NMR (300 MHz, CDCl 3 ) δ ppm 6.46 (s, 2H), 6.32 (d, J=3.40 Hz, 1H), 3.71 (s, 6H), 2.46 (t, J=3.44 Hz, 1H), 2.38-2.44 (m, 1H), 1.80-2.03 (m, 1H), 1.53-1.58 (m, 2H), 1.26 (s, 6H), 1.16-1.24 (m, 7H), 1.14 (s, 3H), 1.03-1.12 (m, 3H), 1.00 (s, 3H), 0.85 (t, J=6.74 Hz, 3H). Exact mass calculated for C 28 H 42 O 4 m/e 428.29; found 428.98. Anal. calcd. for C 28 H 42 O 4 : C, 75.66; H, 9.41. Found: C, 74.81; H, 9.40.
[0250] (1R,4S)-2-(2,6-dimethoxy-4-pentylphenyl)-7,7-dimethylbicyclo[2.2.1] hept-2-ene-1-carboxylic acid (17a, HU-973). The title compound was prepared by the general procedure described for compound 16a (HU-913), using methyl ester 13a (HU-971) 0.075 g (0.194 mmol) and LiOH 0.093 g (3.89 mmol) in 1.5 ml of MeOH/H 2 O 3:1. The product was purified by preparative TLC (hexane/ethyl acetate) to give yellowish solid 0.010 g (14%). mp 85-87° C.; 1 H NMR (300 MHz, CDCl 3 ) δ ppm 6.33 (s, 2H), 6.28 (d, J=3.39 Hz, 1H), 3.69 (s, 6H), 2.55 (t, J=7.80 Hz, 2H), 2.45 (t, J=3.48 Hz, 1H), 2.36-2.44 (m, 1H), 1.82-2.03 (m, 2H), 1.55-1.65 (m, 2H), 1.30-1.35 (m, 4H), 1.14 (s, 3H), 1.06-1.12 (m, 1H), 1.00 (s, 3H), 0.90 (t, J=6.84 Hz, 3H). Exact mass calculated for C 23 H 32 0 4 m/e 372.23; found 372.92. Anal. calcd. for C 23 H 32 O 4 : C, 74.16; H, 8.66. Found: C, 73.91; H, 8.80.
[0251] (1 S,4R)-2-(2,6-dimethoxy-4-pentylphenyl)-7,7-dimethylbicyclo[2.2.1] hept-2-ene-1-carboxylic acid (17b, HU-974). The title compound was prepared from 13b (HU-972) by the general procedure described for compound 17a (HU-973). Yellowish solid (21%). mp 84-86° C.; 1 H NMR (300 MHz, CDCl 3 ) δ ppm 6.33 (s, 2H), 6.28 (d, J=3.39 Hz, 1H), 3.69 (s, 6H), 2.55 (t, J=7.80 Hz, 2H), 2.45 (t, J=3.48 Hz, 1H), 2.36-2.44 (m, 1H), 1.82-2.03 (m, 2H), 1.55-1.65 (m, 2H), 1.30-1.35 (m, 4H), 1.14 (s, 3H), 1.06-1.12 (m, 1H), 1.00 (s, 3H), 0.90 (t, J=6.84 Hz, 3H). Exact mass calculated for C 23 H 32 O 4 m/e 372.23; found 372.92. Anal. calcd. for C 23 H 32 0 4 : C, 74.16; H, 8.66. Found: C, 73.60; H, 8.70.
[0252] Synthetic Preparations of Compound (19):
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[0253] (1S,4S)-4,7,7-trimethylbicyclo[2.2.1]hept-2-en-2-yl trifluoromethanesulfonate (19a). The title compound was prepared by the general procedure described for compound 9a, using ketone 18a 0.375 g (2.35 mmol), LDA 1.29 ml (2.58 mmol, 2M solution) and phenyl triflimide 0.943 g (2.64 mmol). The product was purified by silica gel column chromatography (petroleum ether/ether) to give oil 0.514 g (77%). 1 H NMR (300 MHz, CDCl 3 ) δ ppm 5.37 (d, J=1.04 Hz, 1H), 2.45 (d, J=3.48 Hz, 1H), 1.93 (dddd, J=3.43, 3.43, 7.85, 11.61 Hz, 1H), 1.70 (ddd, J=3.12, 8.52, 11.84 Hz, 1H), 1.19-1.38 (m, 2H), 1.08 (s, 3H), 0.97 (s, 3H), 0.78 (s, 3H). Exact mass calculated for C 11 H 15 F 3 O 3 S, 284.07, found, 284.77.
[0254] (1R,4R)-4,7,7-trimethylbicyclo[2.2.1]hept-2-en-2-yl trifluoromethanesulfonate (19b).The title compound was prepared from 18b by the general procedure described for compound 19a. Brownish oil (73%). 1 H NMR (300 MHz, CDCl 3 ) δ ppm 5.37 (d, J=1.04 Hz, 1H), 2.45 (d, J=3.48 Hz, 1H), 1.93 (dddd, J=3.43, 3.43, 7.85, 11.61 Hz, 1H), 1.70 (ddd, J=3.12, 8.52, 11.84 Hz, 1H), 1.19-1.38 (m, 2H), 1.08 (s, 3H), 0.97 (s, 3H), 0.78 (s, 3H). Exact mass calculated for C 11 H 15 F 3 O 3 S, 284.07, found, 284.77.
[0255] Synthetic Preparations of Compound (20):
[0000]
[0256] (1S,4S )-3-(2,6-dimethoxy-4-(2-methyloctan-2-yl)phenyl)-1,7,7-trimethylbicyclo[2.2.1]hept-2-ene (20a, HU-917). The title compound was prepared by the general procedure described for compound 11a (HU-911), using pinacol arylboronate 3 (mixed with 4-alkyl resorcinol dimethylether 1) 0.755 g, enol triflate 19a 0.17 g (0.598 mmol), Pd(PPh 3 ) 4 0.041 g (0.036 mmol) and t-BuNF 0.9 ml (0 9 mmol, 1M solution in THF). The product was purified by silica gel column chromatography (petroleum ether/ether) to give oil 0.185 g (78%), which solidified upon standing at −20° C. mp 33-34° C.; 1 H NMR (300 MHz, CDCl 3 ) δ ppm 6.50 (s, 2H), 5.79 (d, J=3.00 Hz, 1H), 3.76 (s, 6H), 2.60 (d, J=3.51, 1H), 1.81 (m, 1H), 1.64 (m, 1H), 1.60 (m, 1H), 1.55 (m, 2H), 1.31 (m, 1H), 1.28 (s, 6H), 1.17-1.25 (m, 8H), 1.08 (s, 3H), 0.99 (s, 3H), 0.86 (t, J=6.69 Hz, 3H), 0.81 (s, 3H). Exact mass calculated for C 27 14 42 O 2 m/e 398.32; found 398.82. Anal. calcd. for C 27 14 42 0 2 : C, 81.35; H, 10.62. Found: C, 81.50; H, 10.71.
[0257] (1R,4R)-3-(2,6-dimethoxy-4-(2-methyloctan-2-yl)phenyl)-1,7,7-trimethylbicyclo[2.2.1]hept-2-ene (20b, HU-918). The title compound was prepared from 19b by the general procedure described for compound 20a (HU-917). Yellowish solid (77%). mp 32-33° C.; 1 H NMR (300 MHz, CDCl 3 ) δ ppm 6.50 (s, 2H), 5.79 (d, J=3.00 Hz, 1H), 3.76 (s, 6H), 2.60 (d, J=3.51, 1H), 1.81 (m, 1H), 1.64 (m, 1H), 1.60 (m, 1H), 1.55 (m, 2H), 1.31 (m, 1H), 1.28 (s, 6H), 1.17-1.25 (m, 8H), 1.08 (s, 3H), 0.99 (s, 3H), 0.86 (t, J=6.69 Hz, 3H), 0.81 (s, 3H). Exact mass calculated for C 27 H 42 O 2 m/e 398.32; found 398.84. Anal. calcd. for C 27 H 42 O 2 : C, 81.35; H, 10.62. Found: C, 81.56; H, 10.85.
[0258] Synthetic Preparations of Compounds (22, HU-936) and (23, HU-926):
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[0259] (1R,4R)-3-(2,6-dimethoxy-4-pentylphenyl)-1,7,7-trimethylbicyclo[2.2.1]heptan-2-one (22, HU-936). n-BuLi 0.6 ml (0.96 mmol, 1.6 M in hexanes) was added to a precooled (0° C.) solution of 2 0.2 g (0.96 mmol) in 3 ml of diethyl ether. The resulting solution was allowed to stir for 2.5 hrs at room temperature. The solution was then cooled back to 0° C. and transferred dropwise via cannula to a suspension of CuI 0.092 g (0.48 mmol) in 2 ml of diethyl ether at 0° C. The resulting solution was allowed to stir for 30 min and 5 ml of anhydrous DMSO was added. Then the solution of 3-bromocamphor 21 0.086 g (0.37 mmol) in lml of diethyl ether and 1 ml of DMSO at 0° C. was added dropwise via septum. The reaction was then allowed to warm to room temperature and stirred over 15 hrs. The reaction was quenched by the addition of 5 ml of saturated aqueous NH 4 Cl. The water phase was extracted three times with diethyl ether. The combined organic layers were washed three times with brine, dried over MgSO 4 , and the solvent was removed in vacuo. Further purification by silica gel column chromatography (petroleum ether/ether) afforded white crystals of 22 (HU-936) 0.093 g (70%). mp 62° C.; 1 H NMR (300 MHz, CDCl 3 ) δ ppm 6.37 (s, 2H), 3.89 (d, J=4.23 Hz, 1H), 3.72 (s, 6H), 2.55 (t, J=7.87 Hz, 2H), 2.19 (t, J=4.11Hz, 1H), 1.71-1.76 (m, 2H), 1.63 (m, 1H), 1.59 (m, 2H), 1.37 (m, 1H), 1.33-1.36 (m, 4H), 1.02 (s, 3H), 1.002 (s, 3H), 0.97 (s, 3H), 0.91 (t, J=6.93 Hz, 3H). Exact mass calculated for C 23 H 34 O 3 m/e 358.25; found 358.67. Anal. calcd. for C 23 H 34 0 3 : C, 77.05; H, 9.56. Found: C, 77.20; H, 9.63.
[0260] (1R,4R)-3-(2,6-dimethoxy-4-(2-methyloctan-2-yl)phenyl)-1,7,7-trimethylbicyclo[2.2.1]heptan-2-one (23, HU-926). The title compound was prepared by the general procedure described for compound 22 (HU-936), using 1 0.23 g (0.87 mmol), n-BuLi 0.54 ml (0.87 mmol, 1.6 M in hexanes), CuI 0.083 g (0.44 mmol), 3-bromocamphor 21 0.069 g (0.3 mmol). Further purification by silica gel column chromatography (petroleum ether/ether) afforded white crystals of 23 (HU-926) 0.081 g (65%). mp 64-65° C.; 1 H NMR (300 MHz, CDCl 3 ) δ ppm 6.49 (s, 2H), 3.89 (d, J=4.23 Hz, 1H), 3.72 (s, 6H), 2.19 (t, J=4.11 Hz, 1H), 1.71-1.76 (m, 1H), 1.53-1.68 (m, 4H), 1.30-1.42 (m, 1H), 1.26 (s, 6H), 1.15-1.24 (m, 8H), 1.01 (s, 3H), 1.00 (s, 3H), 0.97 (s, 3H), 0.85 (t, J=6.73 Hz, 3H). Exact mass calculated for C 27 H 42 O 3 m/e 414.31; found 414.84. Anal. calcd. for C 27 H 42 O 3 : C, 78.21; H, 10.21. Found: C, 78.39; H, 10.27.
[0261] Synthetic Preparations of Compounds (24, HU-938) and (25, HU-928):
[0000]
[0262] (1R,4R)-3-(2,6-dimethoxy-4-pentylphenyl)-1,7,7-trimethylbicyclo[2.2.1]heptan-2-ol (24, HU-938). Ketone 22 (HU-936) 0.085 g (0.23 mmol) in 1 ml of diethyl ether was added to a precooled (0° C.) solution of LiAlH 4 0.14 ml (0.14 mmol, 1M solution in diethyl ether) in diethyl ether 2 ml. After stirring under reflux for 1 h the reaction mixture was cooled to 0° C. and quenched by addition of EtOAc.
[0263] Water was added to the reaction mixture and it was extracted with 3 portions of diethyl ether, followed by washing with aqueous HCl 10%. The organic phase was dried over MgSO 4 and concentrated in vacuo. Further purification by silica gel column chromatography (ether/petroleum ether) afforded white crystals of 24 (HU-938) 0.078 g (92%). mp 58-60° C.; 1 H NMR (300 MHz, CDCl 3 ) δ ppm 6.44 (s, 2H), 4.52 (d, J=6.96 Hz, J=1.87 Hz, 1H), 4.14-4.17 (m, 2H), 3.82 (s, 6H), 2.56 (t, J=7.70 Hz, 2H), 2.19 (t, J=4.11Hz, 1H), 1.77-1.89 (m, 2H), 1.63 (m, 1H), 1.46-1.70 (m, 3H), 1.23-1.41 (m, 4H), 1.06 (s, 3H), 0.94 (s, 3H), 0.92 (s, 3H), 0.90 (t, J=6.93 Hz, 3H,). Exact mass calculated for C 23 H 36 O 3 m/e 360.27; found 360.65. Anal. calcd. for C 23 H 36 O 3 : C, 76.62; H, 10.06. Found: C, 76.46; H, 10.11.
[0264] (1R,4R)-3-(2,6-dimethoxy-4-(2-methyloctan-2-yl)phenyl)-1,7,7-trimethylbicyclo[2.2.1]heptan-2-ol (25, HU-928). The title compound was prepared by the general procedure described for compound 24 (HU-938), using ketone 23 (HU-926) 0.238 g (0.57 mmol), LiAlH 4 0.345 ml (0.34 mmol).Further purification by silica gel column chromatography (ether/petroleum ether) afforded white crystals of 25 (HU-928) 0.208 g (88%). mp 96-98° C; — 1 H NMR (300 MHz, CDCl 3 ) δ ppm 6.55 (s, 2H), 4.58 (dd, J=8.88 Hz, 1H), 4.14-4.17 (m, 2H), 3.82 (s, 6H), 1.78-1.88 (m, 2H), 1.48-1.61 (m, 5H), 1.29-1.33 (m, 1H), 1.27 (s, 6H), 1.16-1.25 (m, 7H), 1.06 (s, 3H), 0.94 (s, 3H), 0.92 (s, 3H), 0.85 (t, J=6.74 Hz, 3H). Exact mass calculated for C 27 14 44 0 3 m/e 416.33; found 416.90. Anal. calcd. for C 27 H 44 0 3 : C, 77.83; H, 10.64. Found: C, 78.10; H, 10.82.
EXAMPLE 2
In Vitro Binding to Cannabinoid Receptors
[0265] Cell Line Generations and Maintenance
[0266] The cDNA clones for human HA-tagged CB 1 and CB2 receptors were obtained from the Missouri S&T cDNA Resource Center (www.cdna.org) in cloning vector pcDNA3.1+. The vector containing the human CB2 receptor was transfected directly into CHO-KI cells obtained from ATCC. The HA-tagged human CB1 receptor sequence was subcloned into the pef4-V5-HisA vector with Kpnl and Pme1 restriction enzymes and subsequently transfected into CHO-K1 cells. Cells were clonally isolated by limited dilution and screened by immunocytochemistry for expression of the HA tag. Clones expressing the HA tag were then screened by RT-PCR to confirm expression of hCB1 and hCB2 receptor mRNA transcripts (data not shown).
[0267] Cells were maintained in DMEM/F12 media supplemented with 10% fetal bovine serum (FBS), 100 units/ml penicillin and 100 μg/ml streptomycin and 2 mM L-glutamine. Transfected cell lines were maintained with additional 150 ug/ml zeocin for pEF HA-CB1 transfected cells and 500 ug/ml G-418 for pcDNA HA-CB2 transfected cells (all reagents obtained from Invitrogen).
[0268] Membrane Preparation
[0269] Cells were grown to confluence and harvested in ice cold phosphate buffered saline with 5 mM EDTA. Cells were spun at 200×g for 10 min and frozen at −80° C. until required. Cell pellets were thawed with cold 0.32 M sucrose and homogenised with a glass homogeniser. The homogenate was spun at 1000×g for 10 min at 4° C. and the supernatant spun in a Sorvall ultracentrifuge for 30 min at 100,000×g. The pellet was then washed in ice cold water and re-spun twice more. The final pellet was resuspended in 50 mM Tris pH 7.5, 0.5 mM EDTA. Protein concentration was determined using the Dc protein assay kit (BioRad, Hercules, Calif., USA).
[0270] Membrame Competition Binding Assay
[0271] The K d of CP 55,940 in the isolated CB1 and CB2 receptor expressing membranes was previously determined to be 2.3 nM and 1.5 nM, respectively (see Pertwee, R. G. Current Medicinal Chemistry 6 635-664 (1999)). Competition binding assays at 2.5 nM [ 3 H]-CP 55,940 (PerkinElmer) were carried out to determine the K 1 values for tested compounds. Membranes (5-10 μg) were incubated with radioligand and a range of concentrations of test compounds in binding buffer (50 mM Tris pH 7.4, 5 mM MgCl 2 , 1 mM EDTA) with 0.5% (w/v) bovine serum albumin (BSA) (ICP Bio, New Zealand), at 30° C. for 60 min. Stock solutions of putative cannabinoid ligands were prepared in dimethyl sulfoxide to a concentration of 10 mM. Six different final concentrations of compounds were used ranging from 50 μM to 0.1 nM. Non-specific binding was determined in the presence of 1 μM non-radioactive CP 55,940 (Tocris Cookson). Assays were terminated by addition of 2 ml ice cold binding buffer and filtration through GF/C filters (Whatman) pre-soaked in cold binding buffer, followed by two washes in the same buffer.
[0272] Radioactivity was determined by incubation of filters with Irgasafe scintillation fluid (PerkinElmer) and scintillation counting in a Wallac Trilux using Microbeta Trilux software. Data was analysed using the Prism 4.02 programme (GraphPad Software, San Deigo, Calif., USA).
[0273] cAMP Assays
[0274] Cells were seeded at a density of 10,000 cells per well in poly-L-lysine treated 96-well culture plates (BD Biosciences). The following day wells were incubated with 40 μl DMEM/F12 containing 0.5% (w/v) BSA and 0.5 mM 3-isobutyl-1-methylxanthine (Sigma-Aldrich) for 30 minutes prior to 15 min stimulation with 50 μM forskolin (Tocris Cookson) and varying concentrations of indicated compounds at 37° C., 5% CO 2 . Assays were stopped by removal of media and addition of 100% ice cold ethanol. Plates were then frozen for a minimum of two hours before complete evaporation of ethanol. The well contents were then reconstituted in 50 μl cAMP assay buffer (20 mM HEPES pH 7.5 and 5 mM EDTA). Half of the reconstituted sample was transferred to round bottom 96-well plates (Greiner Bio-One GmbH) with 50 μl 0.01% w/v PKA (cAMP dependent protein kinase (Sigma-Aldrich) in 1 mM Na citrate pH 6.5 with 2 mM dithiothreitol) and 25 μl [ 3 H]-cAMP (at 22 nM in cAMP assay buffer) (GE Healthcare, Life Sciences). This was allowed to equilibrate for 3-18 hours. Following this a charcoal slurry (5% (w/v) activated charcoal and 0.2% (w/v) BSA in cAMP assay buffer) was added to the samples and the plates centrifuged at 3000×g, 4° C. for 5 min. Radioactive counts within the supernatant were then determined as described for competition binding assays.
[0275] Membrane [ 35 S] GTPrS Binding Assay
[0276] Human CB2 expressing CHO-K1 membranes (5 μg per incubation mixture) were diluted in 50 mM Tris-HCl (pH 7.5) and 0.5 mM EDTA and added to HU compounds in a pre-mixed incubation cocktail. Final incubation concentrations were 55 mM Tris-HCl (pH 7.4), 1 mM EDTA, 100 mM NaCl, 5 mM MgCl 2 , 0.5% BSA, 50 μM GDP, 0.2 nM [ 35 S]GTP 7 S (PerkinElmer) with varied HU compound concentration and 5 μg membrane. Incubations were continued for 60 minutes at 30° C. in a shaking water bath. Assays were terminated by addition of 2 ml ice cold wash buffer (50 mM Tris-HCl, pH 7.5 and 5 mM MgCl 2 ) and filtration through pre-soaked GF/C filters (Whatman), followed by two further washes. adioactivity was determined as described for competition binding assays.
[0277] Statistiacal Analysis
[0278] Data was analyzed using the Prism 4.02 programme (GraphPad Software, San Deigo, Calif., USA). IC50 and EC50 values, as determined from sigmoidal curves, were generated from drug concentrations plotted in log scale. While the standard error of the mean (SEM) or standard deviation of these values may be calculated while they are in log form the conversion into molar (linear) values becomes uneven and the error is not able to be expressed as “plus or minus” the calculated values. It is possible to display data as an average, plus or minus the standard error of the mean in log form, however, this is not easily interpreted or compared to other values. It was therefore elected to calculate the 95% confidence interval for the mean value in log form and then convert the lower limit, mean and upper limit into the molar (linear) scale. Although the range depicted in this data format often spans a wide range of concentrations, it is a much more user friendly method of displaying data, the data generated in this chapter is comparable to other similar published results of reputable sources (Pertwee et al., 2000). Two-tailed t-tests for statistical analysis between enantiomeric pairs of compounds were performed for CB2 K i values. The Pearson value, an indication of linearity, was determined for K i and IC50 or EC50 results obtained for CB2 receptors in binding, cAMP or GTP 7 S experiments, respectively. To determine if Emax values were significantly different from HU-308, one-way ANOVA was performed with a Bonferroni post-test of selected pairs.
[0279] Results
[0280] Efficacy and Affinity of Binding to CB1 and CB2 Receptors.
[0281] All data was analyzed using Prism 4.02. For binding data the K i was determined from IC 50 values derived from competition binding data fitted with one site competition non-linear regression analysis by Prism 4.02 using the K d values reported above.
[0282] pIC 50 values were determined from cAMP assays by fitting a sigmoidal concentration response curve using Prism 4.02.
[0283] Results shown in Tables 1 and 2 were generated by averaging two independently determined pIC 50 values. Data shown is IC 50 (95% confidence interval). E max values were calculated as a percentage of the maximal response detected in parallel cAMP assays with HU-210 (1,1-Dimethylheptyl-11-hydroxy-tetrahydrocannabinol or (6aR)-trans-3-(1,1-Dimethylheptyl)-6a,7,10,10a-tetrahydro-1-hydroxy-6,6-dimethyl-6H-dibenzo[b,d]pyran-9-methan ol) or HU-308 ([(1R,2R,5R)-2-[2,6-dimethoxy-4-(2-methyloctan-2-yl)phenyl]-7,7-dimethyl-4-bicyclo[3.1.1]hept-3-enyl]methanol) for CB1 and CB2 expressing cells respectively. Data are displayed as the mean±SEM.
[0000]
TABLE 1
Efficacy and affinity of compounds of the invention for the human CB1 and CB2 receptor
Competition Binding Assay
cAMP Assay
CB2 Receptor
CB1 Receptor
CB2 Receptor
CB1 Receptor
95%
95%
95%
95%
Com-
K i
Confidence
K i
Confidence
IC 50
Confidence
IC 50
Confidence
pound
HU-number
(nM)
Interval
(μM)
Interval
(nM)
Interval
E max
(μM)
Interval
E max
12a
HU-907
2514
(829, 7630)
NB
—
NB
—
—
NB
—
—
12b
HU-908
NB
—
NB
—
NB
—
—
NB
—
—
14a
HU-909
56.8
(24.4, 132)
11.7
(4.90, 27.9)
425
(233, 774)
95 ± 6%
NB
—
—
14b
HU-910
6
(5.25, 6)
1.37
(0.53, 3.56)
162
(87.9, 300)
105 ± 12%
NB
—
—
11a
HU-911
84.6 §
(34.9, 204)
NB
—
385
(200, 751)
86 ± 9%
NB
—
—
11b
HU-912
77.1 §
(30.0, 199)
>10 μM
—
239
(159, 358)
107 ± 4%
3.37
(2.79, 4.06)
112 ± 8%
16a
HU-913
81.5
(69.6, 95.6)
NB
—
330
(195, 557)
101 ± 11%
NB
—
—
16b
HU-914
1500
(870, 2570)
NB
—
2290
(1710, 3050)
82 ± 7%
NB
—
—
20a
HU-917
NB
—
NB
—
NB
—
—
NB
—
—
20b
HU-918
NB
—
NB
—
NB
—
—
NB
—
—
23
HU-926
106
(55.3, 204)
NB
—
321
(203, 511)
100 ± 13%
NB
—
—
25
HU-928
230
(36.7, 1450)
NB
—
925
(550, 1560)
101 ± 11%
NB
—
—
22
HU-936
1720
(827, 3560)
NB
—
NB
—
—
NB
—
—
24
HU-938
7910
(4610, 13600)
NB
—
NB
—
—
NB
—
—
15a
HU-969
6460
(4800, 7890)
NB
—
NB
—
—
NB
—
—
15b
HU-970
1270
(634, 2530)
NB
—
1150
(664, 1980)
38 ± 2%*
NB
—
—
13a
HU-971
704
(314, 1580)
NB
—
1530
(810, 2900)
31 ± 4%*
NB
—
—
13b
HU-972
168
(115, 247)
NB
—
313
(220, 446)
48 ± 5%*
NB
—
—
17a
HU-973
1150
(596, 2210)
NB
—
2090
(1340, 3260)
40 ± 6%*
NB
—
—
17b
HU-974
>10 μM
—
NB
—
NB
—
—
NB
—
—
HU-308
14
(8.7, 22.8)
NB
—
117
(89.5, 153)
100 ± 0%
NB
—
—
HU-210
0.00294
Competition binding assays were performed with either CHO-CB1 or CHO-CB2 cellular membranes and cAMP assays in whole cells expressing the indicated receptor. Binding (K i ) and potency (EC50) data is presented as the mean with 95% confidence intervals in parentheses. cAMP derived efficacy data (Emax) is presented as the mean ± SEM. All data was calculated from at least three independent repeats.
*P < 0.01 compared to HU-308 Emax.
§ Enantiomer pair with a lack of statistical significance.
NB = No binding or activity detected at concentrations up to 50 μM.
>10 μM = Displacement of radioactive ligand detected at high concentrations competing ligand but complete displacement curves were not obtained.
[0284] Efficacy of Binding to CB2 Receptors.
[0285] This assay was performed for selected high potency compounds. EC 50 values were determined from [ 35 S]GTPγS assays by fitting a sigmoidal concentration response curve (Table 2 and FIG. 1A-1G ). E max values were calculated as a percentage of the maximal response detected in parallel [ 35 S]GTPγS assays with HU-308. As the E max values are determined on a linear scale (not a log of %) these are displayed as the mean±SEM. A Pearson value of 0.9268, indicating good correlation between the data, was generated by plotting the K i values of compounds against their EC 50 ′s determined by GTPγS assay.
[0000]
TABLE 2
Efficacy of compounds of the invention
for the human CB2 receptor
HU-
Compound
Number
EC 50 (nM)
E max
14a
HU-909
135.5 (45.4, 404)
76 ± 7%*
14b
HU-910
26.4 (10.7, 65.5)
121 ± 7%
11a
HU-911
126.2 (50.7, 315)
94 ± 4%
16a
HU-913
343.6 (151, 785)
98 ± 3%
23
HU-926
184.9 (72.1, 474)
51 ± 6%**
25
HU-928
576.8 (291, 1140)
95 ± 5%
HU-308
18.3 (11.6, 28.8)
100 ± 0%
Data is shown as mean EC50 values with 95% confidence interval values in parentheses. Mean E max values (± SEM) have been normalised to HU-308 E max response.
n = 5
*P < 0.05,
**P < 0.001.
[0286] FIGS. 1A-1G show the GTPγS binding graphs for human CB2 receptor of compounds of the invention: HU-308 ( FIG. 1A ), HU-909 ( FIG. 1B ), HU-910 ( FIG. 1C ), HU-911 ( FIG. 1D ), HU-913 ( FIG. 1E ), HU-926 ( FIG. 1F ) and HU-928 ( FIG. 1G ). Data is shown as [ 35 S]GTPγS binding normalised to maximal HU-308 binding under the same experimental conditions.
EXAMPLE 3
In Vitro Effect of HU-910 on Closed Head Injury
[0287] Closed Head Injury Model and Neurobehavioral Evaluation
[0288] The study was conducted according to the guidelines of the Institutional Animal Care Committee of the Hebrew University. Male Sabra mice weighing 35 to 50 g were used in all experiments. Animals were kept under controlled light conditions with a 12 h/12 h light/dark cycle. Experimental closed head injury (CHI) was induced using a modified weight drop device developed in our laboratory as described previously (Chen et al., 1996). At 1 h after CHI, the functional status of the mice was evaluated according to a set of 10 neurobehavioral tasks, namely the neurological severity score (NSS). This score is based on the ability of the mice to perform 10 different tasks (Beni-Adani et al., 2001) that evaluate their motor ability, balance, and alertness. One point is given for failing to perform a task. The severity of injury is indicated by the initial NSS, which is evaluated 1 h after CHI and is also a reliable predictor of the later outcome. A score of 10 reflects maximal neurologic impairment, and a decrease of NSS during the recovery period indicates partial recovery of function.
[0289] Statistical Analysis
[0290] Data was analyzed using the Prism 4.02 programme (GraphPad Software, San Deigo, Calif., USA). The data are expressed as mean±SEM and statistical significance was assessed with one way analysis of variance (ANOVA) followed by a Dunnett's post-hoc analysis for TNF-α levels. Nonparametric NSS values were compared between the two groups at each time point. These data were analyzed for differences between groups at individual times (and not over time within the same group). Hence, Mann—Whitney tests were used for comparisons.
[0291] In Vivo Experiment 1:
[0292] In this study four groups of mice were subjected to CHI (n=10/group and control n=9), after which the following agents were administered:
Group 1 (Control): Vehicle only (ethanol:cremophor:saline at ratio of 1:1:18), 1 h after CHI. Group 2: HU-910, 0.1 mg/kg, dissolved in vehicle (1:1:18 ethanol:cremophor:saline), i.p. 1 h after CHI. Group 3: HU-910, 1.0 mg/kg, dissolved in vehicle (1:1:18 ethanol:cremophor:saline), i.p. 1 h after CHI. Group 4: HU-910, 10.0 mg/kg, dissolved in vehicle (1:1:18 ethanol:cremophor:saline), i.p. 1 h after CHI.
[0297] The Neurological Severity Score (NSS) was followed during 21 days, and the extent of recovery (measured as ΔNSS=NSS(1 h)—NSS(t)) was calculated and presented in FIG. 2 . It is noted that the most effective dose of HU-910 was 10 mg/kg. At days 5 and 7 post injury, the treated mice displayed a significant greater recovery than the controls (vehicle-treated) or lower doses (HU-910 at 0.1 and 1 mg/kg) treated groups.
[0298] In Vivo Experiment 2:
[0299] In this study four groups of mice were subjected to CHI (n=9/group), after which the following agents were administered:
Group 1(Control): Vehicle only (ethanol:cremophor:saline at ratio of 1:1:18), 1 h after CHI. Group 2: HU-910, 10 mg/kg, dissolved in vehicle (1:1:18 ethanol:cremophor:saline), i.p. 1 h after CHI. Group 3: Specific CB2 antagonist SR144528 (N-[(1S)-endo-1,3,3-trimethylbicyclo[2.2.1]heptan-2-yl]-5-(4-chloro-3-methylphenyl)-1-(4-methylbenzyl)pyrazole-3 carboxamide), (see M. Rinaldi-Carmona, et al. J. Pharmacol. Exp. Ther. 284 (1998) 644-650), 1 mg/kg, i.p. 1 h after CHI. Group 4: Specific CB2 antagonist (SR144528, N-[(1S)-endo-1,3,3-trimethylbicyclo[2.2.1]heptan-2-yl]-5-(4-chloro-3-methylphenyl)-1-(4-methylbenzy)pyrazole-3 carboxamide), 1 mg/kg, i.p. 1 h after CHI and HU-910 10 mg/kg administered 10 min after administration of antagonist. It is noted that groups 3 and 4 were administered in order to verify that HU-910 indeed acts via the CB2 receptor.
[0304] FIG. 3 depicts the extent of recovery of the four groups (measured as ΔNSS=NSS(1 h)—NSS(0), for a period of 24 h to 14 day post CHI), from which it can be appreciated that in the presence of the antagonist alone (Group 3), the recovery was significantly reduced as compared with the control group (Group 1), administered with the vehicle alone. Moreover, the beneficial effect of HU-910 was reduced to a similar extent in the presence of the antagonist (Group 4). These findings suggest that HU-910 exerts its effect via the CB2 receptor. Thus, it is also stipulated that the endogenous ligands, 2-AG and anandamide that exert their neuro-protective effect by stimulating of the CB2 receptors, provide protection at the post-CHI period, such that when the CB2 receptor is blocked (e.g. with antagonist), their effect is eliminated as well, leading to retarded recovery.
[0305] In Vivo Experiment 3:
[0306] In this study four groups of mice were subjected to CHI (n=7-8/group), after which the following agents were administered:
Group 1(Control): Vehicle only (Dimethyl Sulfoxide (DMSO): Tween 80: Saline at ratio of 1:1:18), i.p. 1 h after CHI. Group 2: HU-910, 10 mg/kg, dissolved in Vehicle, i.p. 1 h after CHI. Group 3: Specific CB2 antagonist/inverse agonist AM630 (6-Iodo-2-methyl-1-[2-(4-morpholinyl)ethyl]-1H-indol-3-yl] (4-methoxyphenyl)methanone) (Ross et al. 1999)), dissolved in Vehicle, 1 mg/kg, i.p. 1 h after CHI and HU-910, dissolved in Vehicle, 10 mg/kg administered 10 min after administration of antagonist/inverse agonist. Group 4: Specific CB2 antagonist/inverse agonist AM630 (6-Iodo-2-methyl-1-[2-(4-morpholinyl)ethyl]-1H-indol-3-yl] (4-methoxyphenyl)methanone), dissolved in Vehicle, 1 mg/kg, i.p. 1 h after CHI It is noted that groups 3 and 4 were administered in order to verify that HU-910 indeed acts via the CB2 receptor.
[0311] FIG. 4 depicts the recovery of the four groups measured as ΔNSS, for a period of 1 h to 28 days post CHI, from which it can be appreciated that the beneficial effect of HU-910 (Group 2) was reduced to a similar extent in the presence of the antagonist/inverse agonist (Group 3). These findings suggest that HU-910 exerts its effect via the CB2 receptor.
[0312] In Vivo Effect of HU-914 on Closed Head Injury
[0313] In Vivo Experiment 4:
[0314] In this study four groups of mice were subjected to CHI (n=10/group), after which the following agents were administered:
Group 1 (Control): Vehicle only (ethanol:cremophor:saline at ratio of 1:1:18), 1 h after CHI. Group 2: HU-914, 5 mg/kg, dissolved in vehicle (1:1:18 ethanol:cremophor:saline), i.p. 1 h after CHI. Group 3: HU-914, 10 mg/kg, dissolved in vehicle (1:1:18 ethanol:cremophor:saline), i.p. 1 h after CHI. Group 4: HU-914, 20 mg/kg, dissolved in vehicle (1:1:18 ethanol:cremophor:saline), i.p. 1 h after CHI.
[0319] The Neurological Severity Score (ΔNSS) was followed during 21 days and presented in FIG. 5 . The most effective dose of HU-914 was 5 mg/kg. Starting at 3 days post injury, the treated mice with HU-914 5 mg/kg displayed a significant greater recovery than the controls (vehicle-treated) or higher doses (HU-914 10 mg/kg and 20 mg/kg) treated group.
[0320] In Vivo Experiment 5:
[0321] In this study three groups of mice were subjected to CHI (n=10/group), after which the following agents were administered:
Group 1(Control): Vehicle only (ethanol:cremophor:saline at ratio of 1:1:18), 1 h after CHI. Group 2: HU-914, 5 mg/kg, dissolved in vehicle (1:1:18 ethanol:cremophor:saline), i.p. 1 h after CHI. Group 3: Specific CB2 antagonist/inverse agonist (SR144528, N-[(1S)-endo-1,3 ,3-trimethylbicyclo[2.2.1]heptan-2-yl]-5-(4-chloro-3-methylphenyl)-1-(4-methylbenzyl)pyrazole-3 carboxamide), 1 mg/kg, i.p. 1 h after CHI and HU-914 5 mg/kg administered 10 min after administration of antagonist/inverse agonist.
[0325] FIG. 6 depicts the extent of recovery of the four groups (measured as ΔNSS=NSS(1 h)—NSS(t), for a period of 24 h to 28 day post CHI), from which it can be appreciated that in the presence of the antagonist/inverse agonist (Group 3), the recovery achieved by HU-914 (Group 2) was abolished and reduced to a similar extent as in the control group (Group 1), administered with the vehicle alone. These findings suggest that, at least partially, HU-914 exerts its effect via the CB2 receptor.
[0326] In Vivo Experiment 6:
[0327] In this study four groups of male, C57B1 mice were subjected to CHI (n=7-10/group), after which the following agents were administered:
Group 1 (Control): Vehicle only (ethanol:cremophor:saline at ratio of 1:1:18), i.p. 1 h after CHI. Group 2: HU-914, 2.5 mg/kg, dissolved in vehicle (1:1:18 ethanol:cremophor:saline), i.p. 1 h after CHI. Group 3: HU-914, 5 mg/kg, dissolved in vehicle (1:1:18 ethanol:cremophor:saline), i.p. 1 h after CHI. Group 4: HU-914, 10 mg/kg, dissolved in vehicle (1:1:18 ethanol:cremophor:saline), i.p. 1 h after CHI.
[0332] The Neurological Severity Score (NSS) was followed during 14 days and presented in FIG. 7 . It is noted that the most effective doses of HU-914 in a particular strain of mice were 2.5 mg/kg and 5 mg/kg. At days 14 post injury, the treated mice with HU-914 (2.5 mg/kg and 5 mg/kg) displayed a significant greater recovery than the controls (vehicle-treated) or higher dose (HU-914 at 10 mg/kg) treated group. Similar to Sabra mice, this study represents a dose-response effect of HU-914 in C57B1 mice, in which the lower doses (HU-914 2.5 and 5 mg/kg) were more effective than a higher dose (HU-914 10 mg/kg) or vehicle.
[0333] The Effect of HU-914 on TNF-α Production Following CHI.
[0334] TNF-α activity can be induced by ischemic and traumatic brain injury starting at 1-2 h and reaching the peak at 4 h following CHI. (Shohami et al., 1997). The next step was to investigate the effect of HU-914 on TNF-a production after CHI. Three groups of mice (n=5-6) were subjected to CHI:
Group 1 (Control): Sham controls received anesthesia and skin incision only. Group 2: Vehicle only (ethanol:cremophor:saline at ratio of 1:1:18), i.p. 1 h after CHI. Group 3: HU-914, 5 mg/kg, dissolved in vehicle (1:1:18 ethanol:cremophor:saline), i.p. 1 h after CHI.
[0338] The animals were sacrificed 4 hrs after CHI by decapitation. Brains were rapidly removed and dissected into ipsilateral and contralateral cortical and hippocampal segments that were frozen in liquid nitrogen and kept at -78. The brain tissues were homogenized in ice-cold lysis buffer (50 mM Tris-HCl, 1 mM EDTA, 1 mM EGTA, 0.5 mM Na 3 VO 4 , 0.1% 2-mercaptoethanol, 1% Triton X-100, 50 mM NaF, 5 mM sodium pyrophosphate, 10 mM sodium β-glyceropyrophosphate, 0.1 mM phenylmethanesulfonyl fluoride, and protease inhibitor mixture) (Roche Diagnostics, Indianapolis, IN). Following sonication on ice for 45 s and centrifugation at 12,000 rpm for 20 min, protein concentrations in the supernatants were determined using the Bradford method (Bio-Rad Laboratories, Munich, Germany). Supernatants were analyzed by enzyme-linked immunosorbent assay (ELISA) for production of TNF-α, using cytokine specific kit from R&D Systems (Minneapolis, Minn.). HU-914 inhibited TNF-α production in the hippocampus of the injured, left hemisphere, but did not affect the cytokine's level in the left cortex. TNF-α elevation was not detected in the right cortex or hippocampus ( FIG. 8 ).
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The present invention relates to arylated camphenes, processes for their preparation and uses thereof for the manufacture of medicaments for the treatment of diseases, disorders or conditions associated with, or benefiting from stimulation of CB2 receptors.
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BACKGROUND OF THE INVENTION
The present invention relates to the art of earth boring and more particularly to an earth boring cutter with a thread-on replaceable cutting element.
Conventionally, rotary drilling apparatus and particularly rotary drilling apparatus for boring large diameter holes and tunnels includes a multiplicity of roller cutters. A number of the roller cutters together with their bearings and the saddles in which the cutters and bearings are mounted are positioned on a rotary head or a bit body and used to form holes in the formation being bored. The roller cutters may be conveniently mounted on the rotary cutting head of a tunneling machine or on the body of a raise bit. The cutters may be disc type cutters or full face cutters.
A disc type roller cutter is effective in very soft to medium formations. The disc is usually a heat treated alloy steel cutter with an included angle between about 60° and 90°. The disc cutters are usually indexed two or three inches apart. In effect, the disc cutters plow concentric circles around the face of the formation being bored. The cutting discs are indexed so that the formation between discs will break out completely under a given load and R. P. M. This is a very efficient way to cut formations because the cuttings come off the face in relatively large pieces. Disc cutters are not economical in harder formations because the discs dull out quickly in the harder abrasive formations. This is especially detrimental in shaft drilling or raise drilling operations where trip time is costly. It is not practical to make the discs completely of carbide and the brazing on of continuous sintered carbide tips or wedges is also of questionable feasibility from an economical and operational standpoint. Since the bearing life of the roller cutters long outlasts the life of the cutting structure, the cutting structure should be replaced periodically thereby extending the useful lifetime of the cutter. Replacement should be easily possible in the field.
DESCRIPTION OF PRIOR ART
A general indication of the nature of the prior art relating to roller disc type cutters may be obtained from a consideration of the disclosures in the following U.S. patents. In U.S. Pat. No. 3,139,148 to J. S. Robbins, patented June 30, 1964, a rotary boring head having roller cutter discs is shown. A plurality of roller cutter discs are mounted on a support plate adapted to rotate about a horizontal axis. In U.S. Pat. No. 3,216,513 to R. J. Robbins, et al, patented Nov. 9, 1965, cutter assemblies for rock drilling are shown. The cutter assemblies comprise a rotary cutting wheel having a peripheral cutting portion, mounting means including anti-friction bearings on which the cutting wheel is freely rotatable and resiliently cushioned metal-to-metal seal means outboard of the bearings. In U.S. Pat. No. 2,766,977 to J. S. Robbins, patented Oct. 16, 1965, a rotary cutter head for boring type continuous mining machines is shown. The cutter head includes a plurality of integrally connected wheels or rollers which cooperate with each other to effect a plurality of cutting and breaking actions against adjacent cores causing the cores to break easily and continuously thereby allowing rapid and continuous advance of the boring machine. In U.S. Pat. No. 3,444,939 to K. G. Bechem, patented May 20, 1969, a cutting roller for roller type enlarging bits is shown. The cutting roller projects through an opening in a shield. The shield is conical and the cutting ribs of the roller make contact with the rock to be cut along lines generally parallel to the shield face. In U.S. Pat. No. 3,204,710 to K. G. Bechem, patented Sept. 7, 1965, an enlarging roller cutter is shown. According to the invention there is provided an enlarging roller cutter with one annular tooth disposed on a roller base member, characterized in that the annular tooth is disposed at the forward free end of a roller base member, and a free surface is left behind the said annular tooth, said cutter being designed to widening or enlarging a previously drilled or pilot hole. In U.S. Pat. No. 3,572,452 to D. F. Winberg, patented Mar. 30, 1971, a rolling cutter and seal therefor are shown. The cutter includes at least one bit having an encircling ring or an O-ring base. The bits have a cutting edge formed by two flat surfaces. The flat surfaces may be considered to be planes that rise to an edge. The bits are pressed into circular grooves in the rolling cutter body. In U.S. Pat. No. 3,596,724 to K. G. Bechem, patented Aug. 3, 1971, a cutting roller is shown. The cutting roller has two circumferentially extending parallel cutting ribs. Each rib is provided with a series of wear resistant exchangeable inserts which protect the crown and flank surface of the rib against wear.
The use of replaceable cutting elements in the related drill bit art is known and a representative indication of this art may be obtained from a consideration of the disclosures of the following patents. In U.S. Pat. No. 3,426,860 to G. A. Peterson, patented Feb. 11, 1969, a pilot bit with replaceable teeth is shown. The bit body contains a plurality of tooth holding sockets, a plurality of removable teeth and retainers for holding the teeth in the sockets. In U.S. Pat. No. 1,678,201 to J. P. Samuelson, patented July 24, 1928, a rotary drill bit is shown. The bit includes a cutting element which is formed of identical segments having elongated slots to accommodate bolts and permit the segments to be adjusted or replaced. In U.S. Pat. No. 1,143,275 to H. R. Hughes, patented June 15, 1915, a demountable cutting edge for drilling tools is shown. The cutting edge consists of a cutting or shearing blade in the form of a ring having its outer periphery formed with a knife edge. Set screws hold the cutting or shearing blade in place.
SUMMARY OF THE INVENTION
The present invention provides a cutter for an earth boring system that has a rotary unit which bores into earth formations to form a hole therein. The rotary unit functions to disintegrate the formations being bored and fracture rock in a manner that causes fragments of the formation to be separated from the formation being bored. The cutter of the present invention is rotatably connected to the rotary unit and adapted to contact the formations. A replaceable cutting element is mounted on the periphery of the cutter. The replaceable cutting element allows the cutting structure to be replaced in the field. The aforementioned advantages of the present invention and other features and advantages will become apparent from a consideration of the following detailed description of the invention when taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustration of a cutter constructed in accordance with the present invention positioned in a saddle that is adapted to be connected to a rotary unit of an earth boring system.
FIG. 2 is an exploded view of the cutter shown in FIG. 1.
FIG. 3 is an illustration of another embodiment of the cutter of the present invention.
FIG. 4 is an illustration of still another embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIGS. 1 and 2, a roller disc cutter constructed in accordance with the present invention and generally designated by the reference numeral 10 is illustrated. The cutter 10 includes a cutter shell 11 positioned around a bearing shell 12 with bearing shell 12 being securely locked in a saddle mount 13. The saddle mount 13 may be connected to the rotary head of an earth boring machine or to the body of a bit for boring a large diameter hole. The bearing shell 12 is locked in position in the saddle mount 13 by a pin 14 and a retainer element 15. The retainer element is driven through a hole in the saddle mount. The bearing shell 12 remains firmly locked in place throughout the drilling operation due to a tenon and groove arrangement disclosed in U.S. Pat. No. 3,203,492 to C. L. Lichte, patented Aug. 31, 1965.
A multiplicity of bearing systems including a series of ball bearings 16, a series of inner roller bearings 17 and a series of outer roller bearings 18 promote rotation of the cutter shell 11 about the bearing shell 12. Lubricant is retained in the bearing area by two sets of seal elements. The inner set of seal elements includes a pair of annular metal seal rings 19 and 20 that are positioned near the inner end of the cutter 10. A flexible rubber O-ring 21 is positioned between seal ring 19 and the bearing shell 12 to retain the seal ring 19 in the desired position and resiliently urge seal ring 19 against seal ring 20. A flexible rubber O-ring 22 is positioned between the cutter shell 11 and the seal ring 20 to retain the seal ring 20 in the desired position and resiliently urge the seal ring 20 against seal ring 19. The outer set of seal elements includes a pair of annular metal seal rings 23 and 24 that are positioned near the outer end of cutter 10. A flexible O-ring 25 is positioned between the seal ring 24 and bearing shell 12 to retain the seal ring 24 in the desired position and resiliently urge seal ring 24 against seal ring 23. A flexible rubber O-ring 26 is positioned between the cutter shell 11 and seal ring 23 to retain seal ring 23 in the desired position and resiliently urge seal ring 23 against seal ring 24.
A section 31 of the outer surface of the cutter shell 11 is threaded with threads 29. The portions of the outer surface of the cutter shell 11 on each side of the threads 29 remain smooth and are not threaded. A shoulder 9 is provided adjacent the threads 29. An annular cutting element 27 is positioned around the cutter shell 11. The inside surface of the annular ring 27 is provided with threads 30. The threads 30 mate with the threads 29 on the cutter shell 11. One side of the annular ring 27 abuts against the shoulder 9. The outer surfaces of the cutting element 27 slope in wedge fashion to form cutting edge 28. In operation the edge 28 rolls along the formations to form a kerf therein. Portions of the formation between adjacent kerfs fracture out to form the desired hole.
The cutter 10 used in the proper earth boring operation will self-lock the cutting structure 27 to the cutter body 11 until replacement is required at the end of the cutting structure's service life. The replaceable cutting structure 27 may consist of steel or other abrasion resistant materials such as tungsten carbide or a combination of such materials. The locking occurs due to the shoulder 9 on the cutter body 11. Looking at the rotation of the cutter from the gage end toward the center of the head, clockwise rotation requires left-hand threads while counterclockwise rotation requires right-hand threads for proper locking of the cutting structure 27 to the body 11. Removal of a worn cutting structure only requires unthreading the cutting structure 27 from the cutter body 11. New cutting structure is inserted by simply hand-tight engagement of threads 29 and 30. The cutting structure 27 may be easily changed in the field with conventional hand tools, thus eliminating the use of expensive and time-consuming methods of conventional cutting structure replacement. The cutter of the present invention eliminates need for furnaces, presses or other impractical field equipment.
The structural details of a cutter 10 constructed in accordance with the present invention having been described, the operation of the cutter 10 will now be considered with reference to FIGS. 1 and 2. The cutter shell 11 is adapted to be mounted in a saddle that is affixed to the rotary head (not shown) of an earth boring machine or to the body of a raise bit. The cutting edge 28 of the cutting element 27 contacts the formations and forms a circular kerf therein. The portions of the formation between adjacent kerfs tend to fracture out and the fragments are separated from the formations being bored to form the desired hole or tunnel. Since the cutting edge 28 of the cutting element 27 generally becomes dull before any of the other elements of the roller cutter fail, it is desirable to replace the cutting element 27.
In order to replace cutting element 27, the retainer element 15 is driven out of place in the saddle mount 13 and pin 14 is removed from the saddle mount 13. The bearing shell 12 and cutter shell 11 are removed from the saddle mount 13. The inner annular cutting element 27 is unthreaded from the cutter shell 11. Generally, the shoulder 9 prevents the matching threads 29 and 30 from becoming tightly engaged and it is possible to unthread the cutting element 27 from the cutter shell 11. On occasions when it is impossible to unthread cutting element 27, the cutting element 27 may be severed and removed. For example, cutting element 27 could be severed at two points approximately 180° apart and the cutting element 27 removed in two sections. A new annular cutting element is threaded onto the cutter shell 11. The cutter shell 11 and bearing shell 12 are again inserted in the saddle mount 13. The pin 14 and retainer 15 are repositioned in the saddle mount 13 to lock the cutter in place. The cutter 10 is ready for continued operation.
Referring now to FIG. 3, another embodiment of a roller cutter constructed in accordance with the present invention is illustrated. The cutter of this embodiment is a triple disc cutter adapted to form three individual kerfs in the formation being bored. The disc cutter of this embodiment is positioned in a saddle mount in the same fashion that the cutter illustrated in FIGS. 1 and 2 is positioned in a saddle mount. The cutter shell 32 is positioned over a bearing shell (not shown in FIG. 3) and is supported by a bearing system and lubrication system including conventional seal elements.
A first section of the outer surface of the cutter shell 32 is threaded with threads 38. A shoulder 36 is provided adjacent the threads 38. A first annular cutting ring 42 is adapted to be positioned around the cutter shell 32. The inside surface of the annular cutting ring 42 is provided with threads 43. The threads 43 mate with the threads 38 on the cutter shell 32. One side of the annular ring 42 abuts against the shoulder 36. The outer surfaces of the annular cutting ring 42 slope in wedge fashion to form a cutting edge 44. A second section of the outer surface of the cutter shell 32 immediately adjacent the threaded section 38 is provided with a second set of threads 39. A shoulder 37 is provided between the threaded section 39 and the threaded section 38. A second annular cutting ring 45 is adapted to be positioned around the cutter shell 32. The inside surface of the annular cutting ring 45 is provided with threads 46. The threads 46 mate with the threads 39 on the cutter shell 32. The inside surface of the second annular cutting ring 45 has a slightly smaller diameter than the inside surface of the first annular cutting ring 42. One side of annular ring 45 abuts against the shoulder 37. The outer surfaces of the cutting ring 45 slope in wedge fashion to form a cutting edge 47. A third section of the outer surface of the cutter shell 32 is threaded with a third set of threads 41. A shoulder 40 is provided between the threaded portion 41 and the threaded portion 39. A third annular cutting ring 48 is adapted to be positioned around the cutter shell 32. The inside surface of the annular cutting ring 48 is provided with threads 49. The threads 49 mate with the threads 41 on the cutter shell 32. The inside diameter of the third annular ring 48 is slightly smaller than the inside diameter of the second annular cutting ring 45. One side of the annular ring 48 abuts against the shoulder 40. The outer surfaces of the cutting ring 48 slope in wedge fashion to form a cutting edge 50. In operation, the cutting edges 44, 47, and 50 roll along the formations to form three individual kerfs therein. Portions of the formation between adjacent kerfs tend to fracture out to form the desired hole.
When the cutter shown in FIG. 3 is used in the proper earth boring operation, the annular cutting rings 42, 45, and 48 will self-lock to the cutter shell 32 until replacement is required at the end of the service life of the annular cutting rings 42, 45, and 48. The replaceable cutting rings 42, 45, and 48 may consist of steel or other abrasion resistant materials such as tungsten carbide or a combination of such materials. The locking occurs due to the shoulders 36, 37, and 40 on the cutter body 32. Looking at the rotation of the cutter from the gage end toward the center of the head, clockwise rotation requires left-hand threads while counterclockwise rotation requires right-hand threads for proper locking of the cutting rings 42, 45, and 48 to the body 32. Removal of the cutting rings require only unthreading the cutting structures from the cutter body. New cutting structures are inserted by simply hand-tight engagement of the respective threaded sections 38 and 43, 39 and 46, and 41 and 49. The annular cutting ring 42 having the largest inside diameter, is threaded on cutter shell 32 first. The intermediate cutting ring 45 is threaded on second and the cutting ring 48 having the smallest inside diameter is threaded on the cutter shell 32 last. The cutting structures may be easily changed in the field with conventional hand tools, thus eliminating the use of expensive and time-consuming methods of conventional cutting structure replacement. The cutter of the present invention eliminates the need for furnaces, presses, or other impractical field equipment.
Referring now to FIG. 4, another embodiment of a cutter constructed in accordance with the present invention is illustrated. The cutter is designated generally by the reference number 51. The cutter 51 includes an outer cutter shell 53 threaded on an inner cutter shell 54. The outer cutter shell 53 will self-lock until replacement is required at the end of the cutting structure's service life. At that time, the outer cutter shell 53 may be removed by unthreading it from the inner cutter shell 54. A new cutter shell may be inserted in its place and the earth boring operation continued. The outer cutter shell 53 includes a multiplicity of carbide inserts arranged to form a series of annular rows 70-77. The individual carbide inserts are designated by the reference number 69. The outer cutter shell 53 is threaded onto the inner cutter shell 54 and together they are positioned around a bearing shell 55. The bearing shell 55 is securely locked in a saddle 52. The saddle 52 may be connected to the rotary head of an earth boring machine or to the body of an earth boring bit. It is to be understood that the cutter 51 could also be in the form of a conical cutter adapted to be journaled on one of the arms of a rotary rock bit.
The bearing shell 55 is locked in position in the saddle 52 by a main pin 67 and a retainer nail or roll pin 68. The bearing shell 55 remains firmly locked in place throughout the drilling operation due to a tenon and groove arrangement disclosed in U.S. Pat. No. 3,203,492 to C. L. Lichte, patented Aug. 31, 1965. A multiplicity of bearing systems including series of ball bearings 61, a series of inner roller bearings 62 and a series of outer roller bearings 60 promote rotation of the inner and outer cutter shells 53 and 54 about the bearing shell 55. Lubricant is retained in the bearing area by two sets of seal elements. The inner set of seal elements includes a pair of annular metal seal rings 64 and 66 that are positioned near the inner end of the cutter 51. A flexible rubber O-ring 65 is positioned between seal ring 66 and the bearing shell 55 to retain the seal ring 65 in the desired position and resiliently urge seal ring 66 against seal ring 64. A flexible rubber O-ring 63 is positioned between the inner cutter shell 54 and the seal ring 64 to retain the seal ring 63 in the desired position and resiliently urge the seal ring 64 against the seal ring 66. The outer set of seal elements includes a pair of annular metal seal rings 57 and 59 that are positioned near the outer end of the cutter 9. A flexible rubber O-ring 56 is positioned between the seal ring 57 and bearing shell 55 to retain the seal ring 56 in the desired position and resiliently urge seal ring 57 against seal ring 59. A flexible O-ring 58 is positioned between the inner cutter shell 54 and seal ring 59 to retain seal ring 59 in the desired position and resiliently urge seal ring 59 against seal ring 57.
The structural details of cutter 51 having been described, the operation of the cutter 51 will now be considered with reference to FIG. 4. The inner and outer cutter shells 53 and 54 are adapted to be mounted in the saddle 52 that is affixed to the rotary head (not shown) of an earth boring machine or to the body of a raise bit. The cutting inserts 69 contact the formation and form the desired borehole or tunnel. Should the outer cutter shell and cutting structure thereon become worn or damaged before the other elements of the cutter 51 fail, it is desirable to replace the outer cutter shell 53. In order to replace the outer cutter shell 53, the retainer element 68 is driven out of place in the saddle mount 52 and pin 67 is removed from the saddle mount 52. The bearing shell 55 and inner and outer cutter shells 53 and 54 are removed from the saddle mount 52. The outer cutter shell 53 is unthreaded from the inner cutter shell 54. On occasions when it is impossible to unthread outer cutter shell 53, the cutter shell may be severed and removed. A new outer cutter shell is threaded onto the inner cutter shell 54. The inner and outer cutter shells and bearing shell 55 are again inserted in the saddle mount 52. The pin 67 and the retainer 68 are repositioned in the saddle mount 52 to lock the cutter in place. The cutter 51 is ready for continued operation.
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A cutter with a replaceable cutting element is adapted to be mounted upon the rotary head of an earth boring machine or upon the body of an earth boring bit. The cutter is used in conjunction with an earth boring machine that functions to form a borehole or tunnel in the formation being bored. The cutter may operate to fracture rock between a proximate pair of kerfs in a manner to cause fragments of the formation to be separated from the formation being bored or may crush and disintegrate the formation. At least one annular cutting element is mounted on the periphery of the cutter body for contacting the formations. The cutter body includes an external annular threaded surface between the ends of the cutter body. The cutting element includes a threaded inner surface that mates with the threads on the cutter body. A locking shoulder on the cutter body is in contact with a locking shoulder on the cutting element.
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[0001] This claims the benefit of European Patent Application EP 13305420.5, filed Mar. 29, 2013 and hereby incorporated by reference herein.
[0002] The present invention relates to a rail vehicle with fuel consumers and an on board fuel storage and supply system and to a method for storing and supplying fuel in a rail vehicle.
BACKGROUND
[0003] A rail vehicle with on board fuel storage and supply is known from EP 1 847 413 B1. Here, a diesel engine and heater are supplied with fuel via supply lines from an onboard fuel tank.
[0004] The drawback of this known solution, in particular when it is used in motor train sets with multiple railcars, is its inefficient use of available installation space. Said solution takes up most of the installation space, which is no longer available for other components of the rail vehicle, such as additional driving units.
[0005] Document U.S. Pat. No. 5,566,712 provides a further example of a known rail vehicle with on board fuel storage and supply system.
SUMMARY OF THE INVENTION
[0006] It is an object of the present invention to provide a rail vehicle with an on board fuel storage and supply system and corresponding method that allow for better use of installation space available on the rail vehicle.
[0007] The present invention provides a rail vehicle including a first railcar, a second railcar, fuel consumers and an on board fuel storage and supply system characterised in that:
[0008] the first railcar has first fuel consumers and a main fuel tank providing fuel to said first fuel consumers;
[0009] the second railcar has second fuel consumers and a buffer fuel tank providing fuel to said second fuel consumers; and
the on board fuel storage and supply system has a fuelling device for transferring fuel from the main fuel tank to the buffer fuel tank.
[0011] The object is also achieved by a method for storing and supplying fuel in a rail vehicle, characterised in that the rail vehicle includes a first railcar with first fuel consumers and a main fuel tank providing fuel to said first fuel consumers, and a second railcar with second fuel consumers and a buffer fuel tank providing fuel to said second fuel consumers, the method comprising the steps of fuelling the main fuel tank to a desired main level, operating the rail vehicle, during operation of the rail vehicle, fuelling the buffer fuel tank to a desired buffer level and maintaining the buffer fuel tank's fuel level at the desired buffer level by transferring fuel from the main fuel tank to the buffer fuel tank.
[0012] By concentrating the fuel storage in a main fuel tank in the first railcar, the size of the fuel tank of the second railcar can be considerably reduced to a small buffer fuel tank. Hence, more installation space is available at the second railcar, which can be used e.g. for additional driving units.
[0013] According to preferred embodiments, the inventive rail vehicle may include one, several or all of the following features, in all technically feasible combinations:
[0014] the fuelling device comprises a fuel line network for conveying fuel from the main fuel tank to the buffer fuel tank, and a main fuel supply pump located in the fuel line network for installation in the second railcar and for sucking fuel from the main fuel tank to the buffer fuel tank;
[0015] the fuelling device further comprises an auxiliary fuel supply pump located in the fuel line network for installation in the first railcar and for pushing fuel from the main fuel tank to the buffer fuel tank;
[0016] the fuel line network further comprises a fuel supply pump bypass, preferably with a check valve, for the or each fuel supply pump;
[0017] the fuelling device further comprises a controller for controlling the main fuel supply pump and the auxiliary fuel supply pump, wherein the controller is adapted to switch the fuelling device between a normal fuelling mode, wherein the main fuel supply pump supplies fuel to the buffer fuel tank while bypassing the idle auxiliary fuel supply pump via the corresponding bypass, and a fail-safe fuelling mode, wherein the auxiliary fuel supply pump supplies fuel to the buffer fuel tank while bypassing the idle main fuel supply pump via the corresponding bypass;
[0018] the fuelling device further comprises a fuel flow sensor in the fuel line network upstream of the buffer fuel tank for detecting fuel flow to the buffer fuel tank, said fuel flow sensor being connected to the controller, wherein the controller is adapted to switch the fuelling device from the normal fuelling mode to the fail-safe fuelling mode if the fuel flow sensor fails to detect fuel flow to the buffer fuel tank;
[0019] the fuel flow sensor comprise a fuel chamber with a fuel inlet and a fuel outlet, the inlet and the outlet being dimensioned such that fuel in the fuel chamber is maintained at a predetermined level at normal fuel flow to the buffer fuel tank, and a fuel level switch for detecting whether the fuel level in the fuel chamber is at said predetermined level and thus indicating normal or abnormal fuel flow to the buffer fuel tank to the controller;
[0020] the fuelling device comprises a low fuel level switch and a high fuel level switch inside the buffer fuel tank, wherein the fuelling device is adapted to start fuelling of the buffer fuel tank when the low fuel level switch indicates a low level of fuel in the buffer fuel tank, and keep on fuelling the buffer fuel tank as long as the high fuel level switch fails to indicate a high level of fuel in the buffer fuel tank;
[0021] the fuelling device has two low fuel level switches and two high fuel level switches inside the buffer fuel tank;
[0022] the fuelling device comprises a one-way fuel flow member, such as a spring-loaded check valve, preventing fuel from flowing from the buffer fuel tank to the main fuel tank;
it comprises a third railcar with a secondary fuel tank, wherein the fuelling device is adapted to transfer fuel from the main fuel tank via the secondary fuel tank to the buffer fuel tank; the fuelling device is adapted to stop the transfer of fuel from the main fuel tank to the secondary fuel tank if the fuel level in the main fuel tank falls below a critical threshold; a pressure relief member, such as a spring-loaded check valve, is connected in anti-parallel to the or each fuel supply pump such that the pumped fuel circulates in a closed loop between the pressure relief member and its corresponding fuel supply pump if the fuel pressure inside the fuel line network exceeds a predetermined threshold; the first railcar has a single internal combustion engine as the first fuel consumers; the second railcar has at least two internal combustion engines as the second fuel consumers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The invention will now be described in detail with reference to the drawings, wherein:
[0029] FIG. 1 shows a first embodiment of an inventive rail vehicle with two railcars;
[0030] FIG. 2 illustrates the on board fuel storage and supply system of the rail vehicle of FIG. 1 ;
[0031] FIG. 3 shows the fuelling device of the system of FIG. 2 ;
[0032] FIGS. 4 and 5 are views of the fuel tanks used in the rail vehicle of FIG. 1 ;
[0033] FIG. 6 is a graph showing the fuel level vs. time in the fuel tanks when performing the inventive method;
[0034] FIG. 7 shows a second embodiment of an inventive rail vehicle with three railcars;
[0035] FIG. 8 illustrates the on board fuel storage and supply system of the rail vehicle of FIG. 7 ; and
[0036] FIG. 9 is a perspective view of the additional fuel tank of the rail vehicle of FIG. 7 .
DETAILED DESCRIPTION
First Embodiment
[0037] With reference to FIG. 1 , there is shown a rail vehicle 10 , namely a motor train set or diesel multiple unit (DMU) with a first railcar 12 and a second railcar 14 . Preferably, DMU 10 is a regional train intended to run on non-electrified railways. More precisely, FIG. 1 shows the DMU manufactured by the applicant under the trade name “Coradia Lint 54/3”.
[0038] The first railcar 12 is fitted with one power bogie 16 and one running bogie 18 . The power bogie 16 includes a driving unit 20 with a diesel engine known in the art as a “powerpack”. In addition to the driving unit 20 , the first railcar has a second fuel consumer, namely a heater 22 . Powerpack 20 and heater 22 are supplied with fuel from a main fuel tank 24 located next to running bogie 18 via fuel conduits 25 .
[0039] Second railcar 14 is fitted with two power bogies 26 and 28 . Each power bogie 26 , 28 includes a respective powerpack 30 , 32 . The second railcar 14 also has a heater 34 . The fuel consumers 30 , 32 , 34 are supplied with fuel from a buffer fuel tank 36 located between the two power bogies 26 , 28 via fuel conduits 37 .
[0040] A fuelling device 38 connects the main fuel tank 24 to the buffer fuel tank 36 . The fuelling device 38 runs from the first railcar 12 to the second railcar 14 .
[0041] The fuelling device 38 , the fuel tanks 24 , 36 and the fuel conduits 25 , 37 together form an on board fuel storage and supply system 40 of the DMU 10 .
[0042] The on board fuel storage and supply system 40 is shown in greater detail in FIG. 2 . The left hand side of FIG. 2 corresponds to the second railcar 14 , and the right hand side corresponds to the first railcar 12 . Vertical dotted lines S represent the boundary of each railcar 12 , 14 . The fuel level in each fuel tank 24 , 36 is indicated by a horizontal line H and the fuel itself by the letter F.
[0043] Each fuel consumer 20 , 22 , 30 , 32 and 34 is supplied with fuel via a corresponding fuel supply device 42 . A heat exchanger 43 may be provided between two adjacent fuel supply devices 42 . Since each fuel supply device 42 is identical (apart from the simplified fuel supply devices of powerpack 32 and heater 34 that have no fuel pump), only one of them will be described.
[0044] Fuel supply device 42 includes a fuel intake 44 , a fuel return line 46 and a fuel pump assembly 48 . Fuel intake 44 extends from the bottom 50 of the respective fuel tank to the respective fuel consumer. Fuel return line 46 extends from the fuel consumer to the bottom 50 of the respective fuel tank. The fuel pump assembly 48 is located in the fuel intake 44 . Each fuel pump assembly 48 comprises a fuel pump unit 52 and a check valve 54 connected in parallel. The fuel pump unit 52 includes a fuel conveying pump 56 and a spring-loaded check valve 58 connected in anti-parallel.
[0045] Each fuel tank 24 , 36 is fitted with a fuel level indicator 60 , an air vent (such as a throttle valve) 62 , and a gate valve 63 . The main fuel tank 24 also has two fuel filler necks 64 , one for each lateral side of the DMU 10 , and, in some implementations, two dry couplings 66 . The buffer fuel tank 36 lacks any fuel filler necks.
[0046] The fuelling device 38 is shown in detail in FIG. 3 . It comprises a fuel line network 68 for conveying fuel from the main fuel tank 24 to the buffer fuel tank 36 , a main fuel supply pump unit 70 located in the fuel line network 68 and installed in the second railcar 14 , an auxiliary fuel supply pump unit 72 located in the fuel line network 68 and installed in the first railcar 12 , and a controller 74 for controlling the main fuel supply pump unit 70 and the auxiliary fuel supply pump unit 72 .
[0047] The main fuel supply pump unit 70 comprises a main fuel supply pump 76 and a pressure relief member 78 , such as a spring-loaded check valve, connected in anti-parallel.
[0048] The auxiliary fuel supply pump unit 72 comprises an auxiliary fuel supply pump 80 and a pressure relief member 82 , such as a spring-loaded check valve, connected in anti-parallel.
[0049] The fuel line network 68 includes a fuel supply pump bypass 84 , 86 preferably with a check valve 88 , 90 for each fuel supply pump 76 , 80 . The bypass check valve 88 , 90 is connected in parallel to its respective fuel supply pump unit 70 , 72 .
[0050] A one-way fuel flow member 92 , such as a spring-loaded check valve, is arranged between the main fuel supply pump unit 70 and the buffer fuel tank 36 .
[0051] The fuel line network 68 extends over the two railcars 12 and 14 , with a first part P 1 of the network being installed in first railcar 12 , and a second part P 2 of the network being installed in second railcar 14 . A fuel connection assembly 94 connects the two parts P 1 and P 2 . The fuel connection assembly 94 comprises a first fuel coupling 96 , such as a dry break coupling, fitted onto the first railcar 12 , a second fuel coupling 98 , such as a dry break coupling, fitted onto the second railcar 14 , and a fuel hose 100 extending between the two fuel couplings 96 , 98 .
[0052] The fuelling device 38 also comprises a fuel flow sensor 102 between the one-way fuel flow member 92 and the buffer fuel tank 36 . This fuel flow sensor 102 comprises a fuel chamber 104 with a fuel inlet 106 and a fuel outlet 108 , and a fuel level switch 110 .
[0053] Furthermore, the fuelling device 38 includes two low fuel level switches LO and LU and two high fuel level switches V 1 and V 2 inside the buffer fuel tank 36 .
[0054] Controller 74 has a signal connection 112 to the main fuel supply pump 76 , the auxiliary fuel supply pump 80 , and the fuel level switches 110 , LO, LU, V 1 and V 2 .
[0055] FIG. 4 is a perspective view of buffer fuel tank 36 . Buffer fuel tank 36 has a generally cuboid shape. Its preferred volume is of the order of 0.08 Cbm. The fuel chamber 104 of fuel flow sensor 102 is attached to one side wall of buffer fuel tank 36 . The three fuel intakes 44 and three fuel return lines 46 for the three fuel consumers of second railcar 14 are all arranged on the same side of buffer fuel tank 36 .
[0056] FIG. 5 is a top plan view of main fuel tank 24 . Main fuel tank 24 has a generally cuboid shape. Its preferred volume is of the order of 2.7 Cbm. The fuel line network 68 as well as the fuel intakes 44 and fuel return lines 46 are all arranged on the main fuel tank's top side. The auxiliary fuel supply pump unit 72 is fixed to a side wall of main fuel tank 24 .
[0057] The normal operation, also called normal fuelling mode (NM), of the inventive on board fuel storage and supply system 40 will now be described.
[0058] Normal Operation
[0059] The process starts when the DMU 10 is refuelled at a filling station. Depending on which side the filling station is located with respect to DMU 10 , the main fuel tank 24 is filled to a desired fuel level via one of the two fuel filler necks 64 . It is to be noted that buffer fuel tank 36 remains empty at this stage since it is supplied with fuel from the main fuel tank 24 as will be explained later on. Accordingly, refuelling of DMU 10 at a filling station is quick and simple since one only has to fill a single fuel tank. This is in contrast to prior art DMUs where the fuel tank of each railcar needs to be filled individually and thus the DMU has to move along the filling station in several steps as the different fuel tanks are filled.
[0060] Once the refuelling of the DMU 10 is finished, it can then go into service. Once the DMU operates, the low fuel level switch LO indicates a low level of fuel in the buffer fuel tank 36 to controller 74 . As a consequence, controller 74 switches fuelling device 38 into a normal fuelling mode. In this mode, main fuel supply pump 76 is activated and sucks fuel out of main fuel tank 24 into buffer fuel tank 36 . The corresponding path followed by the fuel is indicated by arrows 1 in FIG. 3 . The fuel F leaves the main fuel tank 24 , bypasses the idle auxiliary fuel supply pump 80 via the corresponding bypass 86 , crosses into the second railcar 14 via the fuel connection assembly 94 , runs through the main fuel supply pump 76 and into the buffer fuel tank 36 via the fuel flow sensor 102 .
[0061] The fuelling of the buffer fuel tank 36 is carried on until the high fuel level switch V 1 or V 2 indicates a high level of fuel in the buffer fuel tank 36 to the controller 74 , whereupon the controller 74 deactivates the main fuel supply pump 76 and the fuelling device 38 goes into an idle mode.
[0062] After this initial filling process, buffer fuel tank 36 is regularly refilled once the fuel inside it has been depleted. To this end, controller 74 restarts the normal fuelling mode as soon as the low fuel level switch LO detects a low fuel level inside buffer fuel tank 36 .
[0063] The inventive on board fuel storage and supply system 40 has several fail-safe features, which will now be described.
[0064] Fail-Safe Fuelling Mode
[0065] Let us suppose that the fuelling device 38 has some kind of malfunction, which means that there is not enough fuel reaching the buffer fuel tank 36 . Such a malfunction could for example be due to cold ambient conditions, such as a temperature below −15° C. Under such conditions, the diesel fuel's viscosity increases rapidly and the main fuel supply pump may no longer be able to suck the fuel from the main fuel tank 24 . Another malfunction could be leakage of fuel from the fuel line network 68 .
[0066] When such a malfunction occurs, the fuel flow sensor 102 will fail to detect sufficient fuel flow to the buffer fuel tank 36 during normal fuelling mode. More precisely, the fuel level inside the fuel chamber 104 will drop and the fuel level switch 110 will signal a lack of fuel to the controller 74 . As a consequence, the controller 74 will switch fuelling device 38 into a fail-safe fuelling mode.
[0067] In the fail-safe fuelling mode, the main fuel supply pump 76 is turned off. Instead, the auxiliary fuel supply pump 80 is activated and attempts to push fuel from the main fuel tank 24 to the buffer fuel tank 36 while bypassing the idle main fuel supply pump 76 via the corresponding bypass 84 . The fuel flow path in the fail-safe fuelling mode is indicated by arrows 2 in FIG. 3 . Thanks to its position at the beginning of the fuelling device 38 , the auxiliary fuel supply pump 80 generates high pressure inside the fuel line network 68 . In particular, auxiliary fuel supply pump 80 can push harder than the main fuel supply pump 76 can suck, since the depression generated by the latter cannot go beyond vacuum.
[0068] After the fuelling device 38 has run in fail-safe fuelling mode during a predetermined amount of time, the controller then checks whether the fuel flow sensor 102 now indicates sufficient fuel flow. If it does, the controller 74 issues a warning to the rail vehicle driver indicating a fuel viscosity problem. If does not, the controller 74 issues a warning to the rail vehicle driver indicating a fuel leakage and the risk of engine outage.
[0069] Excess Pressure Protection
[0070] The spring-loaded check valves 82 (cf. FIG. 3 ) act as an excess pressure protection. If the fuel pressure inside the fuel line network 68 exceeds a predetermined threshold, check valve 82 opens. Accordingly, pumped fuel circulates in a closed loop between the check valve 82 and the corresponding fuel supply pump 80 , 76 until the fuel pressure inside the fuel line network 68 drops back below the predetermined threshold.
[0071] Backflow Prevention
[0072] The spring-loaded check valve 92 prevents fuel from flowing back from the buffer fuel tank 36 to the main fuel tank 24 . Furthermore, thanks to the spring, a minimum pressure is required to open check valve 92 in the downstream direction. Hence, unintentional fuel flow to the buffer fuel tank 36 is also prevented. This is particularly useful when the rail vehicle 10 stops on a slope. Without check valve 92 , the gradient would lead to uncontrolled fuel flow from one fuel tank to the other.
[0073] Fuel Level Switch Redundancy
[0074] Two low fuel level switches LO and LU and two high fuel level switches V 1 and V 2 are arranged inside the buffer fuel tank 36 . Thus, if one low fuel level switch and/or one high fuel level switch breaks down, the fuelling device 38 can still operate with the remaining fuel level switches.
[0075] Fuel Level Switch Defect Detection
[0076] The sequence of switching of the fuel level switches LO, LU, V 1 , V 2 is normally always the same. If there is a difference from the expected switching sequence an algorithm, preferably implemented in the vehicle's Train Control Monitoring System (TCMS), recognises a fuel level switch defect and gives a feedback to the driver.
Second Embodiment
[0077] With reference to FIG. 7 , there is shown a rail vehicle 500 , namely a motor train set or diesel multiple unit (DMU) with a first railcar 12 , a second railcar 14 , and a third railcar 502 . Preferably, DMU 500 is a regional train intended to run on non-electrified railways. More precisely, FIG. 7 shows the DMU manufactured by the applicant under the trade name “Coradia Lint 81/4”.
[0078] DMU 500 is essentially a stretched version of DMU 10 , a third railcar 502 having been inserted between the first and second railcars 12 , 14 . In the following, only the differences with respect to DMU 10 will be described. For similar elements, reference is made to the description above in relation to DMU 10 .
[0079] Third railcar 502 includes a secondary fuel tank 504 (preferred volume of around 0.9 Cbm) and two associated fuel consumers, namely a powerpack 506 and a heater 508 . Third railcar 502 has two bogies, one running bogie 510 , and one power bogie 512 powered by powerpack 506 . The secondary fuel tank 504 is illustrated in FIG. 9 . It has a generally cuboid shape and includes an air vent 62 , two fuel filler necks 64 , a fuel level indicator 60 , as well as said fuel level switches V 1 and V 2 .
[0080] Fuelling device 38 comprises a secondary fuelling device 514 for fuelling the secondary fuel tank 504 , and a buffer fuelling device 516 for fuelling buffer fuel tank 36 . The details of fuelling device 38 are shown in FIG. 8 . It will be apparent that secondary fuelling device 514 and buffer fuelling device 516 are both identical to the fuelling device 38 of FIG. 3 and work in the same way. During normal fuelling mode, both the buffer fuel tank 36 and the secondary fuel tank 504 are kept at a desired fuel level by taking fuel from the main fuel tank 24 .
[0081] Fuel Shortage Mode
[0082] In contrast to DMU 10 , DMU 500 features a fuel shortage mode SM. Fuelling device 38 switches into fuel shortage mode if the fuel level in the main fuel tank 24 falls below a critical threshold. In this mode, the transfer of fuel between the three fuel tanks 24 , 36 , 504 is stopped in such a way that all three fuel tanks 24 , 36 , 504 run dry essentially simultaneously. This increases the remaining time/distance that rail vehicle 500 can travel before the fuel runs out completely.
[0083] This fuel shortage mode SM is illustrated by FIG. 6 . The graph in FIG. 6 plots the percentage fuel level V M , V B , V S of main fuel tank 24 , buffer fuel tank 36 , and secondary fuel tank 504 as a function of time t1. Here, at time t0, all three fuel tanks 24 , 36 and 504 start at a fuel level of 100%. Up to time t1, fuelling device 38 runs in normal fuelling mode NM. At time t1, fuel level V M in main fuel tank 24 drops to a critical lower threshold V Crit . This is when secondary fuelling device 514 switches to fuel shortage mode SM. This means that no more fuel is supplied to secondary fuel tank 504 . As a result, fuel level V S in secondary fuel tank 504 starts to drop until it reaches the critical lower threshold V Crit at time t2.
[0084] It will be noted that only main fuel tank 24 needs to be refuelled if DMU 500 reaches the filling station before the start of the fuel shortage mode. Indeed, in this case, secondary fuel tank 504 and buffer fuel tank 36 are still full. If DMU 500 reaches the filling station after the fuel shortage mode has started, both the main fuel tank 24 and the secondary fuel tank 504 need to be refuelled via the fuel filler necks 64 .
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A rail vehicle ( 10 ) with fuel consumers ( 20, 22, 30, 32, 34 ) and an on board fuel storage and supply system, characterised by a main fuel tank ( 24 ) adapted to be installed in a first railcar ( 12 ) of the rail vehicle ( 10 ), a buffer fuel tank ( 36 ) adapted to be installed in a second railcar ( 14 ) of the rail vehicle ( 10 ), and a fuelling device ( 38 ) for transferring fuel from the main fuel tank ( 24 ) to the buffer fuel tank ( 36 ).
Preferred application to internal combustion engine rail vehicles with multiple railcars equipped with multiple diesel engines.
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STATEMENT OF GOVERNMENT INTEREST
The invention described herein may be manufactured and used by or for the Government for governmental purposes without the payment of any royalty thereon.
BACKGROUND OF THE INVENTION
This invention relates generally to a portable system for testing electrical circuits and more specifically to a system which prevents interruption in circuit function during testing.
Normally, testing electric circuits is a relatively simple task. However, in a case where the circuit is formed on a board and the board is a part of a larger system which cannot be practically shut down, the problem becomes more difficult. Those which cause particular difficulty are electronic alarm security systems. These systems include a number of sensing units placed at strategic locations around an area or within a building. All sensors would be connected to a master security panel located in a security office on or off the premises. The advantage to such a system is easily seen where one person can monitor a large panel containing substantial numbers of alarms with a single glance.
Operation of security systems is simple, with a light and/or an audible alarm being activated by the remote sensing detector. Means are provided to allow access without activating the sensor and means are provided to reset the alarm once it has been activated.
Maintenance and repair of the system is far more complex and sensitive than the operation. Since there are usually a number of sensors to any system, there will be a corresponding number of alarm modules mounted, usually in a unified master panel for ease in monitoring. When one module needs maintenance, the particular sensor connected to it has to be shut down. Additionally, as a practical matter, maintenance personnel working around a master security panel tend to disrupt operations, block the panel from the view of security people and tend to cause alarm indications which are attributed to maintenance, thereby masking true alarms.
A typical security system is manufactured by the American District Telegraph Co (ADT) model 5930-018. This system utilizes readout modules in the master panel which are the supervisory and control elements of the alarm system. The readout module consists of a front plate which mounts in the master panel. This plate contains lights for indicating an alarm visually and switches for setting or resetting the alarm system. An audio alarm is also a part of the master panel.
Transverse to the front plate is a circuit board which is hidden behind the front panel when mounted in master panel. The circuit board contains all the necessary circuitry to cause the system to function and contains a plug-in feature whereby readout modules are simply plugged into the master panel.
Readout modules must be periodically checked and readjusted due to changes in temperature, age and line voltage. Occasionally, a malfunction in the system will require that the module be examined for defects.
Currently available maintenance equipment for testing readout modules is difficult to use, particularly in cramped quarters where master panels tend to be located. They contain meters that are difficult to read and their use tends to cause the master panel to be obscured either in whole or in part. Additionally, existing equipment causes the master panel audio alarm signal to function during testing thereby possibly allowing a working active module to be inadvertently compromised.
Additionally, there is no means for bench testing readout modules short of inserting them into an active system. Similarly, there is no way of training personnel on the maintenance of these systems modules except by utilizing an active alarm system.
The invention proposed herein solves the outlined short comings of existing alarm systems.
SUMMARY OF THE INVENTION
The invention is a portable system for testing electronic security alarm modules without interrupting the system security function of that system.
The test system utilizes a card adapter to substitute for the alarm module in the master panel. An extension cord connects the card to the test circuit which is contained in a compact box like enclosure. The alarm module is plugged into the test circuit where it is tested and adjusted. In the event of genuine intrusion the alarm will function normally. The extension cord allows the module to be tested away from the master control panel. Likewise the system will function in the configuration stated for long periods in the event intermittent voltage problems are to be monitored.
The test unit will test for line voltage and current under both "secure" and "access" conditions. Since the test unit contains battery power and is otherwise self-sufficient in lieu of a master control panel, the system will serve as a mock up for bench testing alarm modules. The test unit also contains a pair of test leads, connected by an extension cord for testing voltages.
It is therefore an object of the invention to provide a new and improved portable circuit testing system.
It is another object of the invention to provide a portable circuit testing system for security alarm circuits.
It is a further object of the invention to provide a portable circuit testing system for security alarm circuits that allows the alarm circuit to function during testing.
It is another object of the invention to provide a portable circuit testing system that provides more distinct and more exact readings than any hitherto known system.
It is still a further object of the invention to provide a new and improved alarm circuit test system that enables maintenance in inacessible areas.
It is still another object of the invention to provide a new and improved alarm circuit test system that allows module testing and maintenance apart from a master circuit control system.
It is another object of the invention to provide an alarm circuit test unit that will differentiate between actual alarms and those caused by maintenance and testing.
It is another object of the invention to provide a circuit test unit that is low in cost and simple to operate.
It is another object of the invention to provide a portable electronic circuit test unit that reduces the maintenance time for alarm circuits by twenty five percent.
These and other advantages, features and objects of the invention will become more apparent from the following description taken in connection with the illustrative embodiment in the accompanying drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a pictorial representation of the test unit.
FIG. 2 is a circuit diagram of the test system.
FIG. 3 is a circuit diagram of the adapter card utilized in the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, the test circuit is contained in a portable carrying case, shown generally at 10. The case is equipped with a carrying means 12 and appropriate clasps 14 to carry accessory equipment on the outside of the case.
On the top of the case are two indicator panels 16, 18 for digitally showing milliamperage and voltage. Also exiting through the top of the case is a flexible cord 20 which ends with two probes 22 for testing voltage. A cord 24 for line power exits through the rear of the case.
The front panel of the unit contains a two way toggle switch 26 which activates or deactivates the milliampere function. Below this switch is a female socket 28 particularly adapted to receive the alarm module being tested. A pin 30 is added below the socket to provide mechanical support for the alarm module.
A fuse 32 is placed immediately above charging indicator light 34. A standard female phone jack 36 is used for line input, which is received from adapter card 38 via flexible line extension or cable 40 and male phone plug 42. The adapter card is equipped with a wooden handling portion 44 and is substituted for the alarm module in the master control panel during maintenance and testing.
Two way function switch 46 provides for line adjustment in the master control panel and module or card test when the alarm module is inserted in socket 28.
For alarm module testing, function switch 48 provides a pair of redundant green luminescent diodes 50 for secure and amber luminescent diodes 52 for the access condition.
Referring now to FIG. 2 a circuit diagram is shown for the test unit. The dashed line surrounding the circuit represents the metal container 10. The circuit is grounded to the case at 54. Input line power (110/220/240 VAC) enters via three wire cord 24 which has its separate wires or lines divided at 56 to separate circuit connections. One line is fused (32) and enters terminal block 58, the other line connects the terminal block directly. From terminal 58 a pair of lines go directly to battery charger 60 with charger light 34, and thence to 6 volt battery 62. Battery power is supplied via lines 64, 66 to female socket 28 and contacts labled S and 8. Power is taken from line 64 to operate buzzer 67 which is connected to contact A on socket 28. Additionally power from line 64 supplies luminescent diodes 50, 52 functioning in conjunction with switch 48 shown in the secure position for a module function test.
Power is also taken from line 66 via line 72 and resistor 74 for switch 46, shown in the line test position for milliampere adjustment. Switch 46 is connected via line 76 to contact 3 on female socket 28.
Line power passing through terminal block 58 is connected via line 78 to digital milliampere meter 16 and voltmeter 18. Cord 20 and probes 22, are connected to the voltmeter. The switch 26 has connections via line 80 to the voltmeter 18 and terminal 58 and also to millimeter 16 via line 82.
Contact 84 of switch 26 is connected in the off position to the female phone jack 36 and milliampere meter 16. Additionally, switch 48 is connected via lines 86 and resistors 88 and 90 to contact 84 of switch 26 and female phone jack 36.
Milliampere meter 16 is connected to contact 13 of socket 28 via line 92 which also connects switch 26 via line 94.
FIG. 3 shows adapter card (38) and connections necessary for the particular alarm system shown as an example herein. Male adapter plug 42 is connected via line 40 to contacts 3 and 13 on the card. Points 8 and S are interconnected through resistor 96 and luminescent diodes 98. A jumper connects contacts H and 7.
In operation an alarm module is removed from the master control panel and an adapter card substituted. The adapter card 38 is plugged into the test unit via phone plug 42. The alarm module is plugged to female socket 28 on the unit and the security system continues to function normally.
Checks are made on the alarm module with the voltage probes 22 and the line adjustment position of switch 46. An internal buzzer is activated when tests are performed on the alarm module, thereby eliminating confusion with other security alarm modules.
In the event a bench test is desired, the alarm module is plugged into the circuit, switch 46 moved to card test and switch 48 moved between secure and access.
The unit may be left in place and the security system operated in the event long term observation of the circuit is required.
Although the invention has been described with reference to a particular embodiment it will be understood to those skilled in the art that the invention is capable of a variety of alternative embodiments within the spirit and scope of the appended claims.
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A portable system for testing and adjusting security alarm system modules where an alarm module is removed from the security system and inserted into the test system, an adapter card, connected to the test system, replaces the module, whereby the alarm system continues to function normally, the alarm circuit is then tested for voltage, current and continuity and necessary adjustments made.
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REFERENCE TO RELATED APPLICATIONS
[0001] This application is the United States national phase application of PCT/DE2006/000155, filed Feb. 2, 2006, which claims priority to German Patent Application No. DE102005006435.3, filed Feb. 12, 2005, the entire content of each application is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention relates generally to a motor vehicle with a roof which is at least partly movable having at least three roof parts and an independently movable roof region.
BACKGROUND OF THE INVENTION
[0003] In order to allow partial roof opening for a motor vehicles with two or more rows of seats, such as sports utility vehicles (SUVs), it is known to have at least three rigid roof parts which are sequential with a closed roof as well as roofs having a flexible region covered with a covering.
[0004] It is the underlying problem of the invention to store the roof parts in their open position in as space-saving a way as possible in a generic motor vehicle.
SUMMARY OF THE INVENTION
[0005] According to one aspect of the invention, a roof opening is made possible for a vehicle having a flexible roof region, wherein the flexible roof region is covered upwardly in its open position without a separate lid part being required therefor. Since the covering is formed by parts of the actual roof, the vertical extent of the stowed roof packet is low so that the space utilization is improved.
[0006] According to another aspect of the invention, a vehicle has at least three roof parts which are capable of opening and which are separate from one another at their outer surface, with an additional flexible roof region also being provided. Since the covering roof parts are disposed sequentially flush in the open position, they can cover a long surface and moreover only require a minimized height.
[0007] if an almost vertical trunk lid advantageously adjoins the roof part or parts disposed in the manner of a lid toward the rear, the trunk lid, together with the upwardly covering plate part or parts of the roof, can tightly border a trunk, in particular when the covering roof part or parts completely covers or cover the roof region disposed below with an open roof.
[0008] With a closed roof, the rear portion of the vehicle can have a side profile similar to a station wagon. With a completely open roof, it can have a side profile similar to a notchback vehicle. Therefore, with a closed roof, an upward enlarging of the trunk is possible and the invention can be utilized for station wagons, vans or SUVs.
[0009] Provided that the vehicle has a flexible roof region and a roof region separately connected to the car body with rigid roof parts, a roof position can advantageously be made possible in which only a rear, flexible roof region provided with a covering is open and the roof region disposed to the front and including rigid roof parts is still disposed above the passenger compartment. The movements of the roof regions can then be made possible via transmissions which are also spatially separate and which each only take up a small constructional space.
[0010] An additional partial opening in the manner of a sliding roof is possible if roof parts disposed horizontally can be transposed over one another during travel in the closed state.
[0011] The vehicle in accordance with the invention can be a full drop-top vehicle for a particularly good open air feeling. Alternatively, it is also possible that frame parts remain in position, for example above lateral window panes.
[0012] The separate connection of the roof region disposed at the front can be realized visually and mechanically favorably with rigid roof parts when the roof region has a pillar part projecting upward from a window beltline and with at least one plate part attached to the pillar part. The pillar part can in particular act in the manner of a pivot lever for the plate part or parts disposed at the front of the movable roof region and can also include a rollover protection.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a schematic side view of a vehicle in accordance with the invention in a four-door configuration having a flexible roof region disposed at the rear and a roof region disposed further to the front with respect to the direction of travel and having rigid roof parts with a closed roof;
[0014] FIG. 2 shows the vehicle in accordance with FIG. 1 in a view from above cut away at the vertical longitudinal center plane;
[0015] FIG. 3 is a similar view to FIG. 1 after opening the flexible rear roof part;
[0016] FIG. 4 is a similar view to FIG. 3 during the opening also of the roof region having rigid roof parts and with an additionally indicated pivoting open of the trunk lid;
[0017] FIG. 5 is a similar view to FIG. 4 with a completely open roof; FIG. 6 shows a section along the line VI-VI in FIG. 1 ; and FIG. 7 shows a section along the line VII-VII in FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
[0018] In FIGS. 1-5 , a motor vehicle according to one embodiment is indicated at 1 . The vehicle 1 is shown illustratively as a four-door, notchback configuration, though other configurations may be used.
[0019] The vehicle 1 includes a flexible rear roof region 3 , which is provided with a covering 4 and a rear window 5 , and a front roof region 6 here including three rigid roof parts 7 , 8 , 9 . Due to the considerable possible roof length allowed by at least three rigid roof parts 7 , 8 , 9 , which are sequentially aligned in the closed position. The vehicle 1 can provide a large passenger compartment having four or more seats in two or three rows. Both the rear roof region 3 and the front roof region 6 are movably connected to the car body. No manual removal of parts of the roof 2 is therefore necessary for opening the roof.
[0020] The front roof region 6 with its roof parts 7 , 8 , 9 , which are substantially rigid, can be made predominantly transparent. Parts respectively covered and forming a rigid frame would also be possible. In every case, the roof parts 7 , 8 , 9 form units separate from one another at their outer surfaces. The plate parts 7 , 8 have practically no arched portion in the longitudinal region of the vehicle and are disposed substantially horizontally over the passenger compartment in their closed position. To affect a partial opening (not shown), at least the first roof part 7 can be transposed above or below the roof part 8 disposed behind it during travel.
[0021] In an alternative configuration (not shown), the rear rigid roof part 9 could also include a rear window 5 and form the rear end of the roof without a flexible roof region 3 being provided. The roof line could then also be configured as a notchback vehicle or a pick-up vehicle having a loading space cover with a closed vehicle.
[0022] A trunk lid 10 is provided at the rear side which is at least almost vertical in the closed state in accordance with the drawing and which is pivotable downwardly or—as shown here in FIG. 4 —upwardly.
[0023] At the outer surface of the roof, the flexible roof region 3 is completely separate from the roof region 6 including the rigid parts 7 , 8 , 9 and also has its own drive transmission so that both roof regions 3 , 6 are movable separately from each other. The connection of the covering of the rear roof part 3 is shown in FIG. 7 . It becomes clear that the covering is fixedly connected peripherally below the window beltline 12 and is therefore automatically tautened by the setting upright of the clamp 13 .
[0024] The vehicle 1 can allow a roof position in which only the flexible rear roof region 3 is open and is stowed below the window breast line 12 , whereas the roof region 6 at the front, in contrast, is disposed closed above the passenger compartment ( FIG. 3 ).
[0025] When the front roof region 6 is also completely open, a free position is achieved which extends from the windshield frame 11 up to the trunk lid 10 so that a full drop-top vehicle is provided without any remaining side frame.
[0026] The roof region 6 including rigid roof parts 7 , 8 , 9 has a pillar part 9 which projects upward from the window beltline 12 and at least one plate part 7 , 8 disposed at the front is movably hung from the pillar part 9 . The pillar part 9 or a linkage covered thereby acts in the manner of a pivot lever for the plate part or parts 7 , 8 disposed at the front during the movement of the roof region 6 so that said plate parts are also transposed downwardly by rearward pivoting of the pillar part 9 . When the roof 2 is closed (FIG. 1 ), a clamp 13 of the flexible roof region 3 sealingly abuts the pillar part 9 which can be continued with a cross member extending transversely over the whole vehicle width and can also include a rollover protection ( FIG. 6 ).
[0027] To open the roof, the clamp 13 is first released from the contact position and pivoted downwardly, with the rear window 5 being pivoted around a rear fixed connection of the covering of the roof region 3 toward the front so that the flexible roof region 3 is moved into the open position in accordance with FIG. 3 . In this position, the rear window 5 is disposed below the clamp 13 and both parts are disposed substantially horizontally in the upper trunk region.
[0028] Parallel to this stowing of the rear roof region 3 or after it, the opening of the front roof region 6 can take place in which the plate parts 7 , 8 are first opened with respect to one another by a pivoting of the pillar part 9 ( FIG. 4 ) in order also to obtain sufficient headroom for the rear seat passengers as well during the opening. In the open position, in contrast, the plate parts 7 , 8 are again generally parallel and sequentially flush in a continuation of the window beltline 12 . In this position, they engage over the flexible roof region 3 and also over the pillar part 9 which is likewise disposed substantially horizontally at the end of the opening movement, in the manner of a lid visible from the outside ( FIG. 5 ), without a body lid having to be provided thereover.
[0029] The retracted roof parts 9 and 3 are completely covered, with a sealing also being able to be provided at the sides and toward the rear with respect to the trunk lid 10 . The sealing permits a completely sealed trunk and folding top reception space thereunder.
[0030] With a completely open roof, an elegant side profile in the manner of a notchback vehicle is produced by the horizontal position of the roof parts 7 , 8 at the level of the window beltline 12 .
[0031] The invention has been described in an illustrative manner. It is, therefore, to be understood that the terminology used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the invention are possible in light of the above teachings. For example, the roof regions 3 , 6 can be able to be moved manually or fully automatically or partially automatically for the movements described. Thus, within the scope of the appended claims, the invention may be practiced other than as specifically described.
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The invention relates to a motor vehicle with a roof, comprising a moving flexible roof region, provided with a cover, embodied such that the roof comprises a further roof region separate from the flexible region and divided into rigid roof sections, whereby in the fully open roof position the flexible roof region lies below a rigid roof section extending over the same in the form of a cover.
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CROSS-REFERENCE TO RELATED PATENT APPLICATION AND CLAIM OF PRIORITY
This application claims priority from Korean Patent Application Nos. 10-2006-0053900, filed on Jun. 15, 2006 and 10-2006-0113901,filed on Nov. 17, 2006, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein in its entirety by reference. Furthermore, this application is a divisional of Applicants' U.S. Pat. No. 7,781,579 issued on the 24 of Aug. 2010, Ser. No. 11/812,260 filed in the U.S. Patent & Trademark Office on 15 Jun. 2007, and assigned to the assignee of the present invention.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a cyclopentaphenanthrene-based compound and to an organic electroluminescent device using the same. More particularly, the present invention relates to a cyclopentaphenanthrene-based compound and to an organic electroluminescent device including an organic layer made of the cyclopentaphenanthrene-based compound.
2. Description of the Related Art
Organic electroluminescent (EL) devices (also referred to as organic light-emitting devices) are active emission display devices that emit light by recombination of electrons and holes in a thin layer (hereinafter, referred to as “organic layer”) made of a fluorescent or phosphorescent organic compound when a current is applied to the organic layer. The organic EL devices have advantages such as lightweight, simple constitutional elements, easy fabrication process, superior image quality, and wide viewing angle. In addition, the organic EL devices can perfectly create dynamic images, achieve high color purity, and have electrical properties suitable for portable electronic equipment due to low power consumption and low driving voltage.
Eastman Kodak Co. developed an organic EL device of a multi-layered structure using an aluminum quinolinol complex layer and a triphenylamine derivative layer (U.S. Pat. No. 4,885,211), and an organic EL device including an organic light-emitting layer made of a low molecular weight material capable of covering a broad emission wavelength range from UV to visible light (U.S. Pat. No. 5,151,629).
Light-emitting devices are self-emission devices and have advantages of a wide viewing angle, good contrast, and rapid response speed. The light-emitting devices can be classified into inorganic light-emitting devices including a light-emitting layer made of an inorganic compound and organic light-emitting devices (OLEDs; also referred to as “organic electroluminescent devices” (organic EL devices)) including a light-emitting layer made of an organic compound. The OLEDs show better brightness, driving voltage, and response speed characteristics and can achieve polychromatic changes, compared to inorganic light-emitting devices, and thus there have been many researches about OLEDs.
Generally, OLEDs have a stacked structure of an anode, an organic light-emitting layer, and a cathode. OLEDs may also have various structures such as anode/hole injection layer/hole transport layer/light-emitting layer/electron transport layer/electron injection layer/cathode or anode/hole injection layer/hole transport layer/light-emitting layer/hole blocking layer/electron transport layer/electron injection layer/cathode.
A material used in OLEDs can be divided into a vacuum deposition material and a solution coating material according to a method of forming an organic layer. The vacuum deposition material must have a vapor pressure of 10 −6 torr or more at 500° C. or less, and may be a low molecular weight material with a molecular weight of 1200 or less. The solution coating material must have high solubility in a solvent to prepare a solution, and mainly includes an aromatic or heterocyclic compound.
In the case of manufacturing an OLED using a vacuum deposition process, manufacturing costs increase due to the use of a vacuum system. In the case of using a shadow mask to form pixels for a natural color display, it is difficult to obtain high resolution pixels. On the other hand, in the case of manufacturing an OLED using a solution coating process such as inkjet printing, screen printing, or spin coating, manufacturing is easy, manufacturing costs are low, and a relatively good resolution can be achieved as compared to the case of using a shadow mask.
However, thermal stability, color purity, etc. of light-emitting molecules of materials that can be used in the solution coating process are inferior to those that can be used in the vacuum deposition process. Even when the light-emitting molecules of the materials that can be used in the solution coating process are excellent in thermal stability, color purity, etc., the materials may be crystallized to grow a crystal size corresponding to a visible light wavelength range after they are made into an organic layer, thereby scattering visible light, resulting in turbidity phenomenon, and pin holes may be formed, thereby causing device degradation.
Japanese Patent Laid-Open Publication No. 1999-003782 discloses an anthracene compound substituted by two naphthyl groups which can be used in a light-emitting layer or a hole injection layer. However, the anthracene compound has poor solubility in a solvent, and an OLED using the compound exhibits unsatisfactory characteristics.
Therefore, there is still need to develop an organic EL device having improved driving voltage, brightness, efficiency and color purity, and good thermal stability.
SUMMARY OF THE INVENTION
The present invention provides a compound and an organic electroluminescent device using the compound.
The present invention provides a cyclopentaphenanthrene-based compound which is available for both dry and wet processes, and has good thermal stability, emission characteristics and charge transport, and an organic EL device using the same.
According to an aspect of the present invention, there is provided a cyclopentaphenanthrene-based compound represented by Formula 1 below:
wherein Y and Q are the same or different and each is a substituted or unsubstituted C2-C30 alkylene group, a substituted or unsubstituted C6-C30 cycloalkylene group, a substituted or unsubstituted C6-C30 arylene group, a substituted or unsubstituted C2-C30 heteroarylene group, or a substituted or unsubstituted C2-C30 alkenylene group;
m is an integer of 0 to 5;
n is an integer of 0 to 5;
R 1 and R 2 are the same or different and each is a hydrogen, a halogen, a cyano group, a hydroxyl group, a substituted or unsubstituted C1-C20 alkyl group, a substituted or unsubstituted C3-C20 cycloalkyl group, a substituted or unsubstituted C2-C30 heterocycloalkyl group, a substituted or unsubstituted C1-C20 alkoxy group, a substituted or unsubstituted C6-C30 aryl group, a substituted or unsubstituted C6-C30 aralkyl group, a substituted or unsubstituted C2-C30 heteroaryl group, R 1 and R 2 may be linked together, and R 1 and R 2 , when linked together, form a substituted or unsubstituted C3-C20 aliphatic ring, a substituted or unsubstituted C5-C30 heteroaliphatic ring, a substituted or unsubstituted C6-C30 aromatic ring, or a substituted or unsubstituted C2-C30 heteroaromatic ring;
R 3 , R 4 , R 5 , R 6 , R 7 , and R 8 are the same or different and each is a hydrogen, a halogen, a cyano group, a hydroxyl group, a substituted or unsubstituted C1-C20 alkyl group, a substituted or unsubstituted C3-C20 cycloalkyl group, a substituted or unsubstituted C2-C30 heterocycloalkyl group, a substituted or unsubstituted C1-C20 alkoxy group, a substituted or unsubstituted C6-C30 aryl group, a substituted or unsubstituted C6-C30 aralkyl group, a substituted or unsubstituted C2-C30 heteroaryl group, —N(G 1 )(G 2 ), or —Si(G 3 )(G 4 )(G 5 ) where G 1 , G 2 , G 3 , G 4 , and G 5 are each independently a hydrogen, a substituted or unsubstituted C1-C20 alkyl group, a substituted or unsubstituted C6-C30 aryl group, a substituted or unsubstituted C2-C30 heteroaryl group, a substituted or unsubstituted C5-C20 cycloalkyl group, or a substituted or unsubstituted C2-C30 heterocycloalkyl group;
Z 1 , Z 2 , Z 3 , and Z 4 are the same or different and each is a substituted or unsubstituted C1-C20 alkyl group, a substituted or unsubstituted C3-C20 cycloalkyl group, a substituted or unsubstituted C2-C30 heterocycloalkyl group, a substituted or unsubstituted C1-C20 alkoxy group, a substituted or unsubstituted C6-C30 aryl group, a substituted or unsubstituted C2-C30 heteroaryl group, a substituted or unsubstituted C6-C30 aralkyl group, a substituted or unsubstituted C8-C30 alkylaryl group, a substituted or unsubstituted C1-C20 alkylene group, a substituted or unsubstituted C6-C30 arylene group, or a substituted or unsubstituted C2-C30 heteroarylene group;
X is a single bond, —CH═CH—, —O—, —S—, —Se—, or —C(R′R″)— where R′ and R″ are the same as R 3 , or —(CH 2 ) p — where p is an integer of 1 to 10; and
o is 0 or 1.
R 1 and R 2 may be linked together to form one of rings represented by Formulae 2 through 5 below:
wherein “R 9 ”s are the same or different and each is a hydrogen, a halogen, a cyano group, a hydroxyl group, a substituted or unsubstituted C1-C20 alkyl group, a substituted or unsubstituted C3-C20 cycloalkyl group, a substituted or unsubstituted C2-C30 heterocycloalkyl group, a substituted or unsubstituted C1-C20 alkoxy group, a substituted or unsubstituted C6-C30 aryl group, a substituted or unsubstituted C6-C30 aralkyl group, a substituted or unsubstituted C2-C30 heteroaryl group, —N(G 1 )(G 2 ), or —Si(G 3 )(G 4 )(G 5 ) where G 1 , G 2 , G 3 , G 4 , and G 5 are each independently a hydrogen, a substituted or unsubstituted C1-C20 alkyl group, a substituted or unsubstituted C6-C30 aryl group, a substituted or unsubstituted C2-C30 heteroaryl group, a substituted or unsubstituted C5-C20 cycloalkyl group, or a substituted or unsubstituted C2-C30 heterocycloalkyl group; and
A is a single bond, —O—, —S—, —(CH 2 ) s — where s is an integer of 1 to 5.
According to an embodiment of the present invention, the cyclopentaphenanthrene-based compound of Formula 1 may be selected from compounds represented by Formulae 6 through 8 below:
wherein Y and Q are the same or different and each is a substituted or unsubstituted C2-C30 alkylene group, a substituted or unsubstituted C6-C30 cycloalkylene group, a substituted or unsubstituted C6-C30 arylene group, a substituted or unsubstituted C2-C30 heteroarylene group, or a substituted or unsubstituted C2-C30 alkenylene group;
m is an integer of 0 to 5;
n is an integer of 0 to 5;
R 1 ′ and R 2 ′ are the same or different and each is a hydrogen, a halogen, a cyano group, a hydroxyl group, a substituted or unsubstituted C1-C20 alkyl group, a substituted or unsubstituted C3-C20 cycloalkyl group, a substituted or unsubstituted C2-C30 heterocycloalkyl group, a substituted or unsubstituted C1-C20 alkoxy group, a substituted or unsubstituted C6-C30 aryl group, a substituted or unsubstituted C6-C30 aralkyl group, a substituted or unsubstituted C2-C30 heteroaryl group;
Z 1 , Z 2 , Z 3 , and Z 4 are the same or different and each is a substituted or unsubstituted C1-C20 alkyl group, a substituted or unsubstituted C3-C20 cycloalkyl group, a substituted or unsubstituted C2-C30 heterocycloalkyl group, a substituted or unsubstituted C1-C20 alkoxy group, a substituted or unsubstituted C6-C30 aryl group, a substituted or unsubstituted C2-C30 heteroaryl group, a substituted or unsubstituted C6-C30 aralkyl group, a substituted or unsubstituted C2-C30 allylaryl group, a substituted or unsubstituted C1-C20 alkylene group, a substituted or unsubstituted C6-C30 arylene group, or a substituted or unsubstituted C2-C30 heteroarylene group;
X is a single bond, —CH═CH—, —O—, —S—, —Se—, or —C(R′R″)— where R′ and R″ are the same as R 3 , or —(CH 2 ) p — where p is an integer of 1 to 10;
o is 0 or 1; and
“R 10 ”s are the same or different and each is a hydrogen, a halogen, a cyano group, a hydroxyl group, a substituted or unsubstituted C1-C20 alkyl group, a substituted or unsubstituted C3-C20 cycloalkyl group, a substituted or unsubstituted C2-C30 heterocycloalkyl group, a substituted or unsubstituted C1-C20 alkoxy group, a substituted or unsubstituted C6-C30 aryl group, a substituted or unsubstituted C6-C30 aralkyl group, a substituted or unsubstituted C2-C30 heteroaryl group, —N(G 1 )(G 2 ), or —Si(G 3 )(G 4 )(G 5 ) where G 1 , G 2 , G 3 , G 4 , and G 5 are each independently a hydrogen, a substituted or unsubstituted C1-C20 alkyl group, a substituted or unsubstituted C6-C30 aryl group, a substituted or unsubstituted C2-C30 heteroaryl group, a substituted or unsubstituted C5-C20 cycloalkyl group, or a substituted or unsubstituted C2-C30 heterocycloalkyl group.
According to another aspect of the present invention, there is provided an organic EL device including: a first electrode; a second electrode; and at least one organic layer interposed between the first electrode and the second electrode, the organic layer including the above-described organic light-emitting compound.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete appreciation of the invention, and many of the attendant advantages thereof, will be readily apparent as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings in which like reference symbols indicate the same or similar components, wherein:
FIGS. 1A through 1C are schematic views illustrating organic EL devices according to embodiments of the present invention; and
FIGS. 2A and 2B are graphs illustrating voltage-efficiency characteristics of organic EL devices according to embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention will now be described more fully with reference to the accompanying drawings, in which exemplary embodiments of the invention are shown.
The present invention provides a cyclopentaphenanthrene-based compound represented by Formula 1 below:
wherein Y and Q are the same or different and each is a substituted or unsubstituted C2-C30 alkylene group, a substituted or unsubstituted C6-C30 cycloalkylene group, a substituted or unsubstituted C6-C30 arylene group, a substituted or unsubstituted C2-C30 heteroarylene group, or a substituted or unsubstituted C2-C30 alkenylene group;
m is an integer of 0 to 5, preferably an integer of 0 to 2;
n is an integer of 0 to 5, preferably an integer of 0 to 2;
R 1 and R 2 are the same or different, and each is a hydrogen, a halogen, a cyano group, a hydroxyl group, a substituted or unsubstituted C1-C20 alkyl group, a substituted or unsubstituted C3-C20 cycloalkyl group, a substituted or unsubstituted C2-C30 heterocycloalkyl group, a substituted or unsubstituted C1-C20 alkoxy group, a substituted or unsubstituted C6-C30 aryl group, a substituted or unsubstituted C6-C30 aralkyl group, a substituted or unsubstituted C2-C30 heteroaryl group. R 1 and R 2 may be linked together, and R 1 and R 2 , when linked together, form a substituted or unsubstituted C3-C20 aliphatic ring, a substituted or unsubstituted C5-C30 heteroaliphatic ring, a substituted or unsubstituted C6-C30 aromatic ring, or a substituted or unsubstituted C2-C30 heteroaromatic ring;
R 3 , R 4 , R 5 , R 6 , R 7 , and R 8 are the same or different and each is a hydrogen, a halogen, a cyano group, a hydroxyl group, a substituted or unsubstituted C1-C20 alkyl group, a substituted or unsubstituted C3-C20 cycloalkyl group, a substituted or unsubstituted C2-C30 heterocycloalkyl group, a substituted or unsubstituted C1-C20 alkoxy group, a substituted or unsubstituted C6-C30 aryl group, a substituted or unsubstituted C6-C30 aralkyl group, a substituted or unsubstituted C2-C30 heteroaryl group, —N(G 1 )(G 2 ), or —Si(G 3 )(G 4 )(G 5 ) where G 1 , G 2 , G 3 , G 4 , and G 5 are each independently a hydrogen, a substituted or unsubstituted C1-C20 alkyl group, a substituted or unsubstituted C6-C30 aryl group, a substituted or unsubstituted C2-C30 heteroaryl group, a substituted or unsubstituted C5-C20 cycloalkyl group, or a substituted or unsubstituted C2-C30 heterocycloalkyl group;
Z 1 , Z 2 , Z 3 , and Z 4 are the same or different and each is a substituted or unsubstituted C1-C20 alkyl group, a substituted or unsubstituted C3-C20 cycloalkyl group, a substituted or unsubstituted C2-C30 heterocycloalkyl group, a substituted or unsubstituted C1-C20 alkoxy group, a substituted or unsubstituted C6-C30 aryl group, a substituted or unsubstituted C2-C30 heteroaryl group, a substituted or unsubstituted C6-C30 aralkyl group, a substituted or unsubstituted C8-C30 allylaryl group, a substituted or unsubstituted C1-C20 alkylene group, a substituted or unsubstituted C6-C30 arylene group, or a substituted or unsubstituted C2-C30 heteroarylene group;
X is a single bond, —CH═CH—, —O—, —S—, —Se—, or —C(R′R″)— where R′ and R″ are the same as R 3 , or —(CH 2 ) p — where p is an integer of 1 to 10; and
o is 0 or 1.
When R 1 and R 2 are linked together, R 1 and R 2 preferably form one represented by Formulae 2 through 5 below:
wherein “R 9 ”s are the same or different and each is a hydrogen, a halogen, a cyano group, a hydroxyl group, a substituted or unsubstituted C1-C20 alkyl group, a substituted or unsubstituted C3-C20 cycloalkyl group, a substituted or unsubstituted C2-C30 heterocycloalkyl group, a substituted or unsubstituted C1-C20 alkoxy group, a substituted or unsubstituted C6-C30 aryl group, a substituted or unsubstituted C6-C30 aralkyl group, a substituted or unsubstituted C2-C30 heteroaryl group, —N(G 1 )(G 2 ), or —Si(G 3 )(G 4 )(G 5 ) where G 1 , G 2 , G 3 , G 4 , and G 5 are each independently a hydrogen, a substituted or unsubstituted C1-C20 alkyl group, a substituted or unsubstituted C6-C30 aryl group, a substituted or unsubstituted C2-C30 heteroaryl group, a substituted or unsubstituted C5-C20 cycloalkyl group, or a substituted or unsubstituted C2-C30 heterocycloalkyl group; and
A is a single bond, —O—, —S—, or —(CH 2 ) s — where s is an integer of 1 to 5.
In particular, in the compounds of Formulae 1-5, R 1 through R 9 serve to enhance film processibility by increasing the solubility and amorphous property of the compounds.
The compound of Formula 1 according to the present invention may be selected from compounds represented by Formulae 6 through 8 below:
wherein Y and Q are the same or different and each is a substituted or unsubstituted C2-C30 alkylene group, a substituted or unsubstituted C6-C30 cycloalkylene group, a substituted or unsubstituted C6-C30 arylene group, a substituted or unsubstituted C2-C30 heteroarylene group, or a substituted or unsubstituted C2-C30 alkenylene group;
m is an integer of 0 to 5, preferably an integer of 0 to 2;
n is an integer of 0 to 5, preferably an integer of 0 to 2;
R 1 ′ and R 2 ′ are the same or different and each is a hydrogen, a halogen, a cyano group, a hydroxyl group, a substituted or unsubstituted C1-C20 alkyl group, a substituted or unsubstituted C3-C20 cycloalkyl group, a substituted or unsubstituted C2-C30 heterocycloalkyl group, a substituted or unsubstituted C1-C20 alkoxy group, a substituted or unsubstituted C6-C30 aryl group, a substituted or unsubstituted C6-C30 aralkyl group, a substituted or unsubstituted C2-C30 heteroaryl group;
Z 1 , Z 2 , Z 3 , and Z 4 are the same or different and each is a substituted or unsubstituted C1-C20 alkyl group, a substituted or unsubstituted C3-C20 cycloalkyl group, a substituted or unsubstituted C2-C30 heterocycloalkyl group, a substituted or unsubstituted C1-C20 alkoxy group, a substituted or unsubstituted C6-C30 aryl group, a substituted or unsubstituted C2-C30 heteroaryl group, a substituted or unsubstituted C6-C30 aralkyl group, a substituted or unsubstituted C2-C30 allylaryl group, a substituted or unsubstituted C1-C20 alkylene group, a substituted or unsubstituted C6-C30 arylene group, or a substituted or unsubstituted C2-C30 heteroarylene group;
X is a single bond, —CH═CH—, —O—, —S—, —Se—, or —C(R′R″)— where R′ and R″ are the same as R 3 , or —(CH 2 ) p — where p is an integer of 1 to 10;
o is 0 or 1; and
“R 10 ”s are the same or different and each is a hydrogen, a halogen, a cyano group, a hydroxyl group, a substituted or unsubstituted C1-C20 alkyl group, a substituted or unsubstituted C3-C20 cycloalkyl group, a substituted or unsubstituted C2-C30 heterocycloalkyl group, a substituted or unsubstituted C1-C20 alkoxy group, a substituted or unsubstituted C6-C30 aryl group, a substituted or unsubstituted C6-C30 aralkyl group, a substituted or unsubstituted C2-C30 heteroaryl group, —N(G 1 )(G 2 ), or —Si(G 3 )(G 4 )(G 5 ) where G 1 , G 2 , G 3 , G 4 , and G 5 are each independently a hydrogen, a substituted or unsubstituted C1-C20 alkyl group, a substituted or unsubstituted C6-C30 aryl group, a substituted or unsubstituted C2-C30 heteroaryl group, a substituted or unsubstituted C5-C20 cycloalkyl group, or a substituted or unsubstituted C2-C30 heterocycloalkyl group.
In the above formula, the “aryl group” refers to a monovalent group having an aromatic ring system and may contain one, two or more ring systems. The two or more ring systems may be attached to each other or may be fused. The “heteroaryl group” refers to an aryl group in which at least one carbon atom is substituted by at least one selected from the group consisting of N, O, S, and P.
The “cycloalkyl group” refers to an alkyl group having a ring system, and the “heterocycloalkyl group” refers to a cycloalkyl group in which at least one carbon atom is substituted by at least one selected from the group consisting of N, O, S, and P.
In the above formula, the alkyl group, the alkoxy group, the aryl group, the heteroaryl group, the cycloalkyl group, and the heterocycloalkyl group may be substituted by at least one substituent selected from the group consisting of —F; —Cl; —Br; —CN; —NO 2 ; —OH; a C1-C20 alkyl group which is unsubstituted or substituted by —F, —Cl, —Br, —CN, —NO 2 , or —OH; a C1-C20 alkoxy group which is unsubstituted or substituted by —F, —Cl, —Br, —CN, —NO 2 , or —OH; a C6-C30 aryl group which is unsubstituted or substituted by a C1-C20 alkyl group, a C1-C20 alkoxy group, —F, —Cl, —Br, —CN, —NO 2 , or —OH; a C2-C30 heteroaryl group which is unsubstituted or substituted by a C1-C20 alkyl group, a C1-C20 alkoxy group, —F, —Cl, —Br, —CN, —NO 2 , or —OH; a C5-C20 cycloalkyl group which is unsubstituted or substituted by a C1-C20 alkyl group, a C1-C20 alkoxy group, —F, —Cl, —Br, —CN, —NO 2 , or —OH; a C2-C30 heterocycloalkyl group which is unsubstituted or substituted by a C1-C20 alkyl group, a C1-C20 alkoxy group, —F, —Cl, —Br, —CN, —NO 2 , or —OH; and —N(G 6 )(G 7 ). At this time, G 6 and G 7 are the same or different and each may be a hydrogen; a C1-C10 alkyl group; or a C6-C30 aryl group substituted by a C1-C10 alkyl group.
In more detail, R 1 -R 10 are the same or different and each may be selected from the group consisting of a hydrogen, a halogen, a cyano group, a hydroxyl group, a substituted or unsubstituted C1-C10 alkyl group, a substituted or unsubstituted C1-C10 alkoxy group, and a substituted or unsubstituted group as follows: a phenyl group, a biphenyl group, a pentalenyl group, an indenyl group, a naphthyl group, a biphenylenyl, an anthracenyl group, an azulenyl group, a heptalenyl group, an acenaphthylenyl group, a phenalenyl group, a fluorenyl group, a methylanthryl group, a phenanthrenyl group, a triphenylenyl group, a pyrenyl group, a chrysenyl group, an ethyl-chrysenyl group, a picenyl group, a perylenyl group, a chloroperylenyl group, a pentaphenyl group, a pentacenyl group, a tetraphenylenyl group, a hexaphenyl group, a hexacenyl group, a rubicenyl group, a coronenyl group, a trinaphthylenyl group, a heptaphenyl group, a heptacenyl group, a pyranthrenyl group, an ovalenyl group, a carbazolyl group, a thiophenyl group, an indolyl group, a purinyl group, a benzimidazolyl group, a quinolinyl group, a benzothiophenyl group, a parathiazinyl group, a pyrrolyl group, a pyrazolyl group, an imidazolyl group, an imidazolinyl group, an oxazolyl group, a thiazolyl group, a triazolyl group, a tetrazolyl group, an oxadiazolyl group, a pyridinyl group, a pyridazinyl group, a pyrimidinyl group, a pyrazinyl group, a thianthrenyl group, a cyclopentyl group, a cyclohexyl group, an oxiranyl group, a pyrrolidinyl group, a pyrazolidinyl group, an imidazolidinyl group, a piperidinyl group, a piperazinyl group, a morpholinyl group, a di(C6-C30 aryl)amino group, a tri(C6-C30 aryl)silyl group, or a derivative thereof.
The term “derivative(s)” refers to a compound derived or obtained from another and containing essential elements of the above-illustrated group(s). Preferably, the term “derivative(s)” refers to the above-illustrated group(s) wherein at least one hydrogen is substituted by a substituent as described above.
The cyclopentaphenanthrene-based compound of the present invention may be selected from the group consisting of compounds represented by Formulae 9 through 46 below, but is not limited thereto:
The compound of Formula 1 according to the present invention can be synthesized using a common synthesis method. For a detailed synthesis method of the compound of the present invention, reference will be made to the reaction schemes in the following synthesis examples.
The present invention also provides an organic EL device including:
a first electrode;
a second electrode; and
an organic layer interposed between the first electrode and the second electrode, the organic layer including at least one compound represented by Formula 1 above.
The compound of Formula 1 above is suitable for an organic layer of an organic EL device, in particular, a light-emitting layer (also referred to as an emissive layer), a hole injection layer, or a hole transport layer.
An organic EL device according to the present invention includes a compound which has good solubility and thermal stability and can form a stable organic layer, and thus, can provide a good driving voltage and enhanced emission characteristics (e.g., color purity), unlike a conventional organic EL device including a less stable organic layer when manufactured using a solution coating process.
The organic EL device according to the present invention can be variously structured. That is, the organic EL device may further include at least one layer selected from the group consisting of a hole injection layer, a hole transport layer, a hole blocking layer, an electron blocking layer, an electron transport layer, and an electron injection layer, between the first electrode and the second electrode.
In more detail, embodiments of the organic EL device according to the present invention are illustrated in FIGS. 1A , 1 B, and 10 . Referring to FIG. 1A , an organic EL device has a stacked structure of first electrode/hole injection layer/hole transport layer/light-emitting layer/electron transport layer/electron injection layer/second electrode. Referring to FIG. 1B , an organic EL device has a stacked structure of first electrode/hole injection layer/light-emitting layer/electron transport layer/electron injection layer/second electrode. Referring to FIG. 10 , an organic EL device has a stacked structure of first electrode/hole injection layer/hole transport layer/light-emitting layer/hole blocking layer/electron transport layer/electron injection layer/second electrode. At this time, at least one of the light-emitting layer, the hole injection layer, and the hole transport layer may include the compound of Formula 1 of the present invention.
A light-emitting layer of the organic EL device according to the present invention may include a red, green, blue, or white phosphorescent or fluorescent dopant. The phosphorescent dopant may be an organometallic compound including at least one element selected from the group consisting of Ir, Pt, Os, Ti, Zr, Hf, Eu, Tb, and Tm.
Hereinafter, a method of manufacturing an organic EL device according to the present invention will be described with reference to FIG. 1C .
First, a first electrode material with a high work function is formed on a substrate using deposition or sputtering to form a first electrode. The first electrode may be an anode. Here, the substrate may be a substrate commonly used in organic EL devices. Preferably, the substrate may be a glass substrate or a transparent plastic substrate which is excellent in mechanical strength, thermal stability, transparency, surface smoothness, handling property, and water repellency. The first electrode material may be a material with good transparency and conductivity, e.g., indium tin oxide (ITO), indium zinc oxide (IZO), tin oxide (SnO 2 ), or zinc oxide (ZnO).
Next, a hole injection layer (HIL) may be formed on the first electrode using various methods such as vacuum deposition, spin-coating, casting, or Langmuir-Blodgett (LB) method.
In the case of forming the hole injection layer using a vacuum deposition process, the deposition conditions vary according to the type of a hole injection layer material, the structure and thermal characteristics of the hole injection layer, etc. However, it is preferred that the hole injection layer is deposited to a thickness of 10 Å to 5 μm at a deposition rate of 0.01 to 100 Å/sec, at a temperature of 100 to 500° C., in a vacuum level of 10 −8 to 10 −3 torr.
In the case of forming the hole injection layer using a spin-coating process, the coating conditions vary according to the type of a hole injection layer material, the structure and thermal characteristics of the hole injection layer, etc. However, it is preferred that the spin-coating is performed at a coating speed of about 2000 to 5000 rpm, and, after the spin-coating, a thermal treatment is performed at a temperature of about 80 to 200° C. for the purpose of solvent removal.
The hole injection layer material may be a compound of Formula 1 as described above. In addition, the hole injection layer material may be a known hole injection material, e.g., a phthalocyanine compound (e.g., copper phthalocyanine) disclosed in U.S. Pat. No. 4,356,429, a Starburst-type amine derivative (e.g., TCTA, m-MTDATA, or m-MTDAPB) disclosed in Advanced Material, 6, p. 677 (1994), or a soluble conductive polymer, e.g., Pani/DBSA (Polyaniline/Dodecylbenzenesulfonic acid), PEDOT/PSS (Poly(3,4-ethylenedioxythiophene)/Poly(4-styrenesulfonate)), Pani/CSA (Polyaniline/Camphor sulfonic acid), or PANI/PSS (Polyaniline)/Poly(4-styrenesulfonate).
The hole injection layer may be formed to a thickness of about 100 to 10,000 Å, preferably 100 to 1,000 Å. If the thickness of the hole injection layer is less than 100 Å, hole injection characteristics may be lowered. On the other hand, if the thickness of the hole injection layer exceeds 10,000 Å, a driving voltage may be increased.
Next, a hole transport layer (HTL) may be formed on the hole injection layer using various methods such as vacuum deposition, spin-coating, casting, or LB method. In the case of forming the hole transport layer using vacuum deposition or spin-coating, the deposition or coating conditions vary according to the type of a used compound, but are generally almost the same as those for the formation of the hole injection layer.
A hole transport layer material may be a compound of Formula 1 as described above. In addition, the hole transport layer material can be a known hole transport material, e.g., a carbazole derivative such as N-phenylcarbazole or polyvinylcarbazole; an amine derivative having an aromatic fused ring system such as N,N′-bis(3-methylphenyl)-N,N′-diphenyl-[1,1-biphenyl]-4,4′-diamine (TPD) or N,N′-di(naphthalene-1-yl)-N,N′-diphenylbenzidine (α-NPD), etc.
The hole transport layer may be formed to a thickness of about 50 to 1,000 Å, preferably 100 to 600 Å. If the thickness of the hole transport layer is less than 50 Å, hole transport characteristics may be lowered. On the other hand, if the thickness of the hole transport layer exceeds 1,000 Å, a driving voltage may be increased.
Next, a light-emitting layer (EML) is formed on the hole transport layer using vacuum deposition, spin-coating, casting, or LB method. In the case of forming the light-emitting layer using vacuum deposition or spin-coating, the deposition or coating conditions vary according to the type of a used compound, but are generally almost the same as those for the formation of the hole injection layer.
The light-emitting layer may include a compound of Formula 1 as described above. At this time, a known fluorescent host material or a known dopant material suitable for the compound of Formula 1 may also be used. The compound of Formula 1 can be used as a phosphorescent host alone or in combination with CBP (4,4′-N,N′-dicarbazole-biphenyl), PVK (poly(n-vinylcarbazole)), etc. A red phosphorescent dopant (e.g., PtOEP, RD 61 (UDC)), a green phosphorescent dopant (e.g., Ir(PPy) 3 (PPy=2-phenylpyridine)), or a blue phosphorescent dopant (e.g., F 2 Irpic) may be used as a phosphorescent dopant.
When the compound of Formula 1 is used as a dopant, the doping concentration of the dopant is not particularly limited. Generally, the content of the dopant is 0.01 to 15 parts by weight based on 100 parts by weight of a host. When the compound of Formula 1 is used as a single host, the doping concentration of a dopant is not particularly limited. Generally, the content of a dopant is 0.01 to 15 parts by weight based on 100 parts by weight of the host. When the compound of Formula 1 is used as a host in combination with another host, the content of the compound of Formula 1 is 30-99 parts by weight based on the total weight (100 parts by weight) of the hosts.
The light-emitting layer may be formed to a thickness of about 100 to 1,000 Å, preferably 200 to 600 Å. If the thickness of the light-emitting layer is less than 100 Å, emission characteristics may be lowered. On the other hand, if the thickness of the light-emitting layer exceeds 1,000 Å, a driving voltage may be increased.
In a case where the light-emitting layer includes a phosphorescent dopant, a hole blocking layer (HBL) may be formed on the hole transport layer using vacuum deposition, spin-coating, casting, or LB method, in order to prevent the diffusion of triplet excitons or holes into an electron transport layer. In the case of forming the hole blocking layer using vacuum deposition or spin coating, the deposition or coating conditions vary according to the type of a used compound, but are generally almost the same as those for the formation of the hole injection layer. An available hole blocking material may be an oxadiazole derivative, a triazole derivative, a phenanthroline derivative, BCP, an aluminum complex, etc.
The hole blocking layer may be formed to a thickness of about 50 to 1,000 Å, preferably 100 to 300 Å. If the thickness of the hole blocking layer is less than 50 Å, hole blocking characteristics may be lowered. On the other hand, if the thickness of the hole blocking layer exceeds 1,000 Å, a driving voltage may be increased.
Next, an electron transport layer (ETL) may be formed using various methods such as vacuum deposition, spin-coating, or casting. In the case of forming the electron transport layer using vacuum deposition or spin-coating, the deposition or coating conditions vary according to the type of a used compound, but are generally almost the same as those for the formation of the hole injection layer. An electron transport layer material serves to stably transport electrons from an electron donor electrode (a cathode) and may be a known material such as an oxazole-based compound, an isoxazole-based compound, a triazole-based compound, an isothiazole-based compound, an oxadiazole-based compound, a thiadiazole-based compound, a perylene-based compound, an aluminum complex (e.g.: Alq3 (tris(8-quinolinolato)-aluminum) BAlq, SAlq, or Almq3), a gallium complex (e.g.: Gaq′2OPiv, Gaq′2OAc, 2(Gaq′2)), etc.
The electron transport layer may be formed to a thickness of about 100 to 1,000 Å, preferably 200 to 500 Å. If the thickness of the electron transport layer is less than 100 Å, electron transport characteristics may be lowered. On the other hand, if the thickness of the electron transport layer exceeds 1,000 Å, a driving voltage may be increased.
An electron injection layer (EIL) may be formed on the electron transport layer in order to facilitate the injection of electrons from a cathode into the light-emitting layer. An electron injection layer material is not particularly limited.
The electron injection layer material may be optionally selected from known materials such as LiF, NaCl, CsF, Li 2 O, or BaO. The deposition conditions of the electron injection layer vary according to the type of a used compound, but are generally almost the same as those for the formation of the hole injection layer.
The electron injection layer may be formed to a thickness of about 1 to 100 Å, preferably 5 to 50 Å. If the thickness of the electron injection layer is less than 1 Å, electron injection characteristics may be lowered. On the other hand, if the thickness of the electron injection layer exceeds 100 Å, a driving voltage may be increased.
Finally, a second electrode is formed on the electron injection layer using vacuum deposition or sputtering. The second electrode may be used as a cathode. A material for forming the second electrode may be metal or alloy with a low work function, an electroconductive compound, or a mixture thereof. For example, the second electrode forming material may be lithium (Li), magnesium (Mg), aluminum (Al), aluminum-lithium (Al—Li), calcium (Ca), magnesium-indium (Mg—In), magnesium-silver (Mg—Ag), etc. The second electrode may also be a transmissive cathode made of ITO or IZO to provide a front-emission type device.
Hereinafter, the present invention will be described more specifically with reference to the following working examples. However, the following examples are for illustrative purposes and are not intended to limit the scope of the invention.
EXAMPLES
Synthesis Example 1
1) Synthesis of 8,9-dihydro-4H-cyclopenta[def]phenanthrene
4H-cyclopenta[def]phenanthrene (4.75 g, 25 mmol) was placed in a Par reactor bottle, and EtOH (200 ml) was added thereto. 5% Pd/C (3.99 g) was added to the reaction solution, and the resultant solution was incubated under a hydrogen pressure of 40 psi for 24 hours. After the reaction was terminated, the reaction solution was filtered, and the filtrate was concentrated under a reduced pressure to give a white product (4.42 g, 90%).
1 H NMR (300 MHz, CDCl 3 , δ): 7.36(2H, d), 7.21(2H, t), 7.12(2H, d), 3.90(2H, s), 3.16 (4H, s)
2) Synthesis of 2,6-dibromo-8,9-dihydro-4H-cyclopenta[def]phenanthrene
8,9-dihydro-4H-cyclopenta[def]phenanthrene (4.42 g, 23 mmol) was placed in a 250 ml round bottom flask (RBF), and CCl 4 (100 ml) was added thereto. The reaction mixture was cooled to 0° C., and Br 2 (7.72 g, 48 mmol) was dropwise added thereto. The reaction solution was incubated for 4 hours and a 10% NaSO 3 solution was added thereto. The organic layer was separated, concentrated under a reduced pressure, and recrystallized from n-hexane to give a titled compound (4.45 g, 55%).
1 H NMR (300 MHz, CDCl 3 , δ): 7.48(2H, s), 7.28(2H, s), 3.85(2H, s), 3.10(4H, s)
3) Synthesis of Compound 1
2,6-dibromo-8,9-dihydro-4H-cyclopenta[def]phenanthrene (4.45 g, 12.7 mmol) in a 250 ml round bottom flask was dissolved with xylene, and o-chloranil (4.15 g) was added thereto at room temperature. The reaction mixture was heated and refluxed in an oil bath for 72 hours. After the reaction was terminated, the reaction solution was cooled and concentrated under a reduced pressure. The residue was purified by silica gel column chromatography (mobile solvent: n-hexane) to give a compound 1 (3.6 g, 81%).
1 H NMR (300 MHz, CDCl 3 , δ): 7.98(2H, s), 7.79(2H, s), 7.73(2H, s), 4.28(2H, s)
4) Synthesis of Compound 2
2,6-dibromo-4H-cyclopenta[def]phenanthrene (2.6 g, 7.7 mmol), t-BuOK (20.8 g, 61.6 mmol), DMSO (20 ml), and HMPA (20 ml) was placed in 50 ml round bottom flask with a syringe. The mixture was stirred for 50 minutes at room temperature and cooled to 0° C. CH 3 l (3.75 ml, 61.6 mmol) was dropped to the mixture with a syringe and the resultant solution was stirred for 30 minutes at 0° C. Then, water (50 ml) and methylene chloride (50 ml) were added to the solution to separate an organic layer. The organic layer was purified by silica gel column chromatography to obtain compound 2 (3.6 g, 80%). 1 H NMR (300 MHz, CDCl 3 , δ): 7.98(2H, s), 7.79(2H, s), 7.73(2H, s), 1.93(m, 6H).
5) Synthesis of Material 1 (Formula 9)
The compound 2 (0.65 g, 1.747 mmol), bis(4-biphenyl)amine (TCI Corp.) (1.40 g, 4.37 mmol), sodium tert-butoxide (0.51 g, 0.5 mmol), Pd 2 (dba) 3 [(tris(dibenzylidene acetone) dipalladium(0))] (0.08 g, 0.087 mmol), and tri(tert-butyl)phosphine (0.017 g, 0.087 mmol) in a 50 ml round bottom flask were dissolved with toluene (10 mL), and the reaction mixture was refluxed for 12 hours. After the reaction was terminated, the reaction solution was cooled to room temperature and extracted with distilled water (100 ml). The combined organic layers were dried over MgSO 4 , concentrated, and purified by silica gel column chromatography. The eluate was concentrated and dried to give a material 1 represented by Formula 9 (1.1 g, yield: 75%).
1 H NMR (300 MHz, CDCl 3 , δ):7.90(2H, s), 7.75(2H, s), 7.72(2H, s), 7.48-6.62 (m, 36H), 1.92(m, 6H).
Synthesis Example 2
1) Synthesis of Compound 3
2,6-dibromo-4H-cyclopenta[def]phenanthrene (2.6 g, 7.7 mmol) and octyl bromide (3.6 g, 18.5 mmol) in a 50 ml round bottom flask were dissolved with toluene (10 ml), and TBAB (tetrabutylammoniumbromide) (0.125 g, 0.385 mmol) was added thereto. A solution of NaOH (3.1 g, 77 mmol) in water (50 ml) was added to the reaction mixture, and the resultant solution was refluxed for two days. After the reaction was terminated, the reaction solution was extracted with chloroform. The organic layer was dried over MgSO 4 , concentrated, and purified by silica gel column chromatography (eluent: n-hexane). The eluate was distilled under a reduced pressure to remove unreacted octyl bromide, thereby giving a compound 2 (3.6 g, 80%).
1 H NMR (300 MHz, CDCl 3 , δ): 7.98(2H, s), 7.79(2H, s), 7.73(2H, s), 1.93(m, 4H), 1.21(m, 20H), 0.87(m, 6H), 0.65(broad s, 4H)
2) Synthesis of Material 2 (Formula 10)
The compound 2 (1 g, 1.747 mmol), diphenylamine (0.88 g, 5.241 mmol), sodium tert-butoxide (0.51 g, 0.5 mmol), Pd 2 (dba) 3 [(tris(dibenzylidene acetone) dipalladium(0))] (0.08 g, 0.087 mmol), and tri(tert-butyl)phosphine (0.017 g, 0.087 mmol) in a 50 ml round bottom flask were dissolved with toluene (10 mL), and the reaction mixture was refluxed for 12 hours. After the reaction was terminated, the reaction solution was cooled to a room temperature and extracted with distilled water (100 ml). The combined organic layers were dried over MgSO 4 , concentrated, and purified by silica gel column chromatography. The eluate was concentrated and dried to give a material 1 represented by Formula 9 (10.9 g, yield: 70%).
1 H NMR (300 MHz, CDCl 3 , δ): 7.98-6.74 (m, 26H), 1.93(m, 4H), 1.21(m, 20H), 0.87(m, 6H), 0.65(broad s, 4H).
Synthesis Example 3
1) Synthesis of 2,6-dibromo-cyclopenta[def]phenanthren-4-one
Benzene (200 ml) was placed in a 250 ml round bottom flask, and the compound 1 (3.6 g, 10.4 mmol) was added thereto. MnO 2 (150 g) was added to the reaction mixture, and the resultant mixture was heated and refluxed in an oil bath for 18 hours. After the reaction was terminated, the reaction solution was filtered to remove MnO 2 , and sufficiently washed with CHCl 3 , THF, and MeOH in sequence. The filtrate was concentrated under a reduced pressure and the residue was recrystallized from acetone to give the titled compound (1.45 g, 39%).
1 H NMR (300 MHz, CDCl 3 , δ): 8.08(2H, s), 7.89(2H, s), 7.74(2H, s)
2) Synthesis of Intermediate A
2-bromobiphenyl (0.68 g, 2.95 mmol) was dissolved in anhydrous THF (10 ml), and the reaction mixture was cooled to −78° C. Then, t-BuLi (3.5 ml) was gradually dropwise added. The reaction mixture was stirred for one hour, and a solution of 2,6-dibromo-cyclopenta[def]phenanthren-4-one (1 g, 2.95 mmol) in anhydrous THF (5 ml) was dropwise added thereto for 30 minutes. After the reaction was terminated, the reaction solution was concentrated under a reduced pressure and extracted with ethylacetate and brine to separate an organic layer. The organic layer was concentrated and the residue was purified by silica gel column chromatography to give an intermediate A (3.6 g).
3) Synthesis of Compound 4
The intermediate A was dissolved in acetic acid (30 ml), and the reaction solution was cooled to 0° C. Then, HCl (1 ml) was dropwise added and the reaction mixture was incubated for two hours. After the reaction was terminated, the reaction solution was filtered and washed with acetic acid and methanol to give a white solid (2 g, 80%).
4) Synthesis of Material 3 (Formula 13)
A material 3 represented by Formula 13 was synthesized in the same manner as in the synthesis of the material 1 of Synthesis Example 1 except that the compound 4 was used instead of the compound 2 and 9H-carbazole was used instead of Bis(4-biphenyl)amine.
1 H NMR (300 MHz, CDCl 3 , δ): 8.10-6.82 (m, 30H)
5) Synthesis of Material 4 (Formula 14)
The compound 4 (1 g, 1.747 mmol), di-naphthalene-2-yl-[4-(4,4,5,5-tetramethyl-[1,3,2]dioxabororane-2-yl)-phenyl]-amine (1.81 g, 3.843 mmol), K 2 CO 3 (1.935 g, 0.014 mmol), tetrakis(triphenylphosphine)palladium (0) (0.4 g, 0.35 mmol), and tetrabutylammoniumbromide (1.13 g, 3.49 mmol) in a 50 ml round bottom flask were dissolved with toluene (10 ml) and THF (10 ml), and the reaction mixture was refluxed for 12 hours. After the reaction was terminated, the reaction solution was cooled to a room temperature and extracted with distilled water (100 ml) to separate an organic layer. The combined organic layers were dried over MgSO 4 , concentrated, and purified by silica gel column chromatography. The eluate was concentrated and dried to give a material 4 represented by Formula 14 (0.8 g, yield: 45%).
1 H NMR (300 MHz, CDCl 3 , δ): 8.15-6.54 (m, 50H)
Synthesis Example 4
1) Synthesis of Intermediate B
2,6-dibromo-cyclopenta[def]phenanthren-4-one (1.0 g, 2.76 mmol) was dissolved in dry ether (30 ml) and THF (10 ml), and phenyl magnesium bromide (3.0M in ether) was added slowly thereto and then the resultant mixture was refluxed for 3 hours. By adding water to the mixture, the reaction was terminated. 1N—HCl solution was added to the mixture until pH of the mixture to be 3-4 and the resultant was extracted with ethyl acetate. The organic layer was dried over anhydrous sodium sulfate, filtered and concentrated under a reduced pressure. The obtained solid was purified by silica gel column chromatography to give a desired compound (0.79 g, 65%).
2) Synthesis of Compound 5
The intermediate B (0.79 g, 1.79 mmol) was dissolved in dry benzene (20 ml) and trifluoromethane sulfonic acid (0.48 ml, 5.38 mmol, 3 eq.) was dropwise added thereto and then the mixture was stirred at 80° C. for 2 hours. The resultant was diluted with water, extracted with ethyl acetate. The organic layer was dried over anhydrous magnesium sulfate, filtered and concentrated to obtain a solid. The obtained solid was purified by silica gel column chromatography to give a desired compound (0.65 g, 63%).
1 H NMR (300 MHz, CDCl 3 , δ): 7.22-7.26(m, 10H), 7.70(s, 2H), 7.80(s, 3H), 8.00(s, 2H)
3) Synthesis of Material 5 (Formula 15)
A material 5 represented by Formula 15 was synthesized in the same manner as in the synthesis of the material 1 of Synthesis Example 1 except that the compound 5 was used instead of the compound 2, and 9H-carbazole was used instead of bis(4-biphenyl)amine.
1 H NMR (300 MHz, CDCl 3 , δ): 8.02-6.89 (m, 32H).
4) Synthesis of Material 6 (Formula 27)
A material 6 represented by Formula 27 was synthesized in the same manner as in the synthesis of the material 1 of Synthesis Example 1 except that the compound 5 was used instead of the compound 2.
1 H NMR (300 MHz, CDCl3, δ): 8.05-7.75(6H, m), 7.55-6.68 (m, 36H).
5) Synthesis of Material 7(Formula 35)
4-bromo triphenylamine 7.6 g (23.45 mmol), aniline 21.85 g (0.235 mol), sodium tert-butoxide 6.76 g (70 mmol). Pd 2 (dba) 3 [(tris(dibenzilidene acetone)dipalladium(0))] 0.86 g (0.938 mmol) and tri(tert-butyl)phosphine 0.23 g (1.173 mmol) in 500 ml round bottom flask were dissolved with toluene 200 ml, and refluxed for 12 hours. After the reaction was terminated, the reaction solution was cooled to room temperature, and 200 ml of distilled water was added thereto to extract an organic layer. The organic layer was dried over MgSO 4 , concentrated, and purified by silica gel column chromatography. The eluate was concentrated and dried to give N,N,N′-triphenyl-p-phenylenediamine (6.71 g, 85%).
The obtained N,N,N′-triphenyl-p-phenylenediamine (3.36 g, 10.0 mmol), compound 5 (2.0 g, 4.0 mmol), sodium tert-butoxide (1.15 g, 12 mmol), Pd 2 (dba) 3 [(tris(dibenzylidene acetone)dipalladium(0))] (0.14 g, 0.16 mmol) and tri(tert-butyl)phosphine (0.04 g, 0.2 mmol) in 100 ml round bottom flask were dissolved with 50 ml of toluene and refluxed for 12 hours. After the reaction was terminated, the reaction solution was cooled to room temperature and 50 ml of distilled water was added thereto to extract an organic layer. The obtained organic layer was dried over MgSO 4 , concentrated, and purified by silica gel column chromatography. The eluate was concentrated and dried to give material 7 represented by Formula 35 (2.91 g, yield: 72%).
1 H NMR (300 MHz, CDCl 3 , δ): 7.86-7.71(6H, m), 7.32-6.64(m, 48H).
Synthesis Example 5
1) Synthesis of Intermediate C
2,6-dibromo-cyclopenta[def]phenanthren-4-one (0.95 g, 2.62 mmol) and phenol (30 ml) were added to a 250 ml 3-neck round bottom flask. The reaction mixture was heated and incubated for five hours while a HCl gas was run into the mixture. After the reaction was terminated, the reaction solution was concentrated under a reduced pressure to remove unreacted phenol. The residue was purified by silica gel column chromatography to give an intermediate C (0.59 g, 42%).
2) Synthesis of Compound 6
The intermediate C (0.95 g, 2.62 mmol) was placed in a 100 ml round bottom flask, and DMF (5 ml) and acetonitrile (20 ml) were added thereto. K 2 CO 3 (1.52 g) and octyl bromide (2.11 g) were sequentially added, and the reaction mixture was heated and refluxed for 18 hours. After the reaction was terminated, the organic layer was separated and purified by silica gel column chromatography to give a compound 4 (0.68 g, 82%).
1 H NMR (300 MHz, CDCl 3 , δ): 7.78 (2H, d) 7.79(2H, s) 7.67 (2H, d) 7.11(4H, dd) 3.89 (4H, t) 1.74 (4H, q) 1.28 (20H, m) 0.88 (6H, m)
4) Synthesis of Material 8 (Formula 38)
A material 8 represented by Formula 38 was synthesized in the same manner as in the synthesis of the material 1 of Synthesis Example 1 except that the compound 6 was used instead of the compound 2, and 9H-carbazole was used instead of bis(4-biphenyl)amine.
1 H NMR (300 MHz, CDCl 3 , δ): 7.85-6.92(30H, m) (4H, dd) 3.89 (4H, t) 1.74 (4H, q) 1.28 (20H, m) 0.88 (6H, m)
5) Synthesis of Material 9 (Formula 39)
A material 9 represented by Formula 39 was synthesized in the same manner as in the synthesis of the material 4 of Synthesis Example 3 except that the compound 6 was used instead of the compound 4.
1 H NMR (300 MHz, CDCl 3 , δ): 7.95-6.75(50H, m) (4H, dd) 3.89 (4H, t) 1.74 (4H, q) 1.28 (20H, m) 0.88 (6H, m)
Evaluation Example
Evaluation of Optical Characteristics of Materials 1-5
The photoluminescence (PL) spectra of the materials in a solution phase and a film phase were measured to evaluate the emission characteristics of the materials.
In order to evaluate optical characteristics of a solution phase, each of the materials 3, 4, 8 and 9 was diluted to a concentration of 10 mM with toluene, and the PL spectra of the diluted solutions were measured using an ISC PC1 spectrofluorometer equipped with a xenon lamp. Also, in order to evaluate optical characteristics of a film phase, quartz substrates were prepared and washed with acetone and pure water. Then, the materials 3, 4, 8 and 9 were spin-coated on the substrates and heated at 110° C. for 30 minutes to form films with a thickness of 1,000 Å. The PL spectra of the films were measured. The results are presented in Table 1 below. As shown in Table 1, it can be seen that the materials according to the present invention have emission characteristics suitable for organic EL devices.
TABLE 1
Material
Solution (λ max )(nm)
Film (λ max )(nm)
3
390
397
4
420
445
8
395
398
9
420
450
Example 1
Organic EL devices having the following structure were manufactured using the material 1 as a hole transport layer, the compound of Formula 47 as a hole injection layer, the compound of Formula 48 as host of the light-emitting layer and the compound of Formula 49 as a dopant of the light-emitting layer: ITO/Formula 47 (200 Å)/material 1 (300 Å)/Formula 48: Formula 49 (300 Å)/Alq3 (40 Å)/LiF (10 Å)/Al (2000 Å).
A 15 Ω/cm 2 (1,000 Å) ITO glass substrate was cut into pieces of 50 mm×50 mm×0.7 mm in size, followed by ultrasonic cleaning in acetone, isopropyl alcohol, and pure water (15 minutes for each) and then UV/ozone cleaning (30 minutes) to form anodes. The compound of Formula 47 (hole injection layers) and the material 1 (hole transport layers) were vacuum deposited on the anodes. A mixture of the compound of Formula 48 and the compound of Formula 49 (weight ratio of 100:5) was vacuum deposited to form light-emitting layers. Then, an Alq3 compound was vacuum deposited to a thickness of 40 Å on the light-emitting layers to form electron transport layers. LiF (10 Å, electron injection layers) and Al (2000 Å, cathodes) were sequentially vacuum-deposited on the electron transport layers to thereby complete organic EL devices as shown in FIG. 1A . The organic EL devices exhibited red emission of 14,000 cd/m 2 at a voltage of 6.0V and efficiency of 5.45 cd/A.
Example 2
Organic EL devices having the following structure were manufactured using the material 3 as a host of a light-emitting layer and the compound of Formula 50 as a dopant of the light-emitting layer: ITO/Formula 47 (200 Å)/α-NPD(300 Å)/material 3: Formula 50 (300 Å)/Alq3 (40 Å)/LiF (10 Å)/Al (2000 Å).
A 15Ω/cm 2 (1,000 Å) ITO glass substrate was cut into pieces of 50 mm×50 mm×0.7 mm in size, followed by ultrasonic cleaning in acetone, isopropyl alcohol, and pure water (15 minutes for each) and then UV/ozone cleaning (30 minutes) to form anodes. The compound of Formula 47 (hole injection layers) and α-NPD (hole transport layers) were vacuum deposited on the anodes. A mixture of the material 3 and RD15 (Formula 50) (weight ratio of 100:10) was vacuum deposited to form light-emitting layers. Then, an Alq3 compound was vacuum deposited to a thickness of 40 Å on the light-emitting layers to form electron transport layers. LiF (10 Å, electron injection layers) and Al (2000 Å, cathodes) were sequentially vacuum-deposited on the electron transport layers to thereby complete organic EL devices as shown in FIG. 1A . The organic EL devices exhibited red emission of 1200 cd/m 2 at a voltage of 10V and efficiency of 4.32 cd/A. The voltage-efficiency characteristics of the organic EL devices are illustrated in FIG. 2A .
Example 3
Organic EL devices having the following structure were manufactured in the same manner as in Example 1 except that α-NPD was used as a hole transport layer and the material 4 as a dopant of the light-emitting layer: ITO/Formula 47 (200 Å)/α-NPD(300 Å)/Formula 48: material 4(300 Å)/Alq3(40 Å)/LiF(10 Å)/Al(2000 Å). The organic EL devices exhibited blue emission of 4600 cd/m 2 at a voltage of 8V and efficiency of 5.4 cd/A.
Example 4
Organic EL devices having the following structure were manufactured in the same manner as in Example 2 except that the material 5 was used as a host of a light-emitting layer: ITO/Formula 47 (200 Å)/α-NPD(300 Å)/material 5: Formula 50 (300 Å)/Alq3(40 Å)/LiF(10 Å)/Al(2000 Å). The organic EL devices exhibited blue emission of 6500 cd/m 2 at a voltage of 10V and efficiency of 7.48 cd/A.
Example 5
Organic EL devices having the following structure were manufactured in the same manner as in Example 1 except that the material 6 as a hole transport layer: ITO/Formula 47 (200 Å)/material 6(300 Å)/Formula 48: Formula 49 (300 Å)/Alq3(40 Å)/LiF(10 Å)/Al(2000 Å). The organic EL devices exhibited blue emission of 15,800 cd/m 2 at a voltage of 6.5V and efficiency of 7.66 cd/A.
Example 6
Organic EL devices having the following structure were manufactured in the same manner as in Example 1 except that the material 7 was used as hole injection layer and α-NPD as a hole transport layer: ITO/material 7 (200 Å)/α-NPD(300 Å)/Formula 48: Formula 49(300 Å)/Alq3(40 Å)/LiF(10 Å)/Al(2000 Å). The organic EL devices exhibited blue emission of 15,000 cd/m 2 at a voltage of 6.0V and efficiency of 6.48 cd/A.
Example 7
Organic EL devices having the following structure were manufactured using the material 8 as a host of light-emitting layer and the compound of Formula 50 as a dopant of light-emitting layer: ITO/PEDOT(400 Å)/material 8: Formula 50 (300 Å)/Alq3(40 Å)/LiF(10 Å)/Al(2000 Å).
A 15Ω/cm 2 (1,000 Å) ITO glass substrate was out into pieces of 50 mm×50 mm×0.7 mm in size, followed by ultrasonic cleaning in acetone, isopropyl alcohol, and pure water (15 minutes for each) and then UV/ozone cleaning (30 minutes) to form anodes. PEDOT-PSS (Al4083) (Bayer) was coated on the anodes and heated in air at 110° C. for 5 minutes and then in a nitrogen atmosphere at 200° C. for 5 minutes to form hole injection layers with a thickness of 400 Å. A mixture of the material 8 (0.1 g) as a host and the compound of Formula 50 (0.01 g) as a dopant (10 parts by weight of the compound of Formula 50 based on 100 parts by weight of the material 8) was spin-coated on the hole injection layers and heated at 100° C. for 30 minutes to form light-emitting layers with a thickness of 300 Å. Then, an Alq3 compound was vacuum deposited to a thickness of 40 Å on the light-emitting layers to form electron transport layers. LiF (10 Å, electron injection layers) and Al (2000 Å, cathodes) were sequentially vacuum-deposited on the electron transport layers to thereby complete organic EL devices as shown in FIG. 1B . The organic EL devices exhibited red emission of 1500 cd/m 2 at a voltage of 9V and efficiency of 4.1 cd/A. The voltage-efficiency characteristics of the organic EL devices are illustrated in FIG. 2B .
Example 8
Organic EL devices having the following structure were manufactured in the same manner as in Example 7 except that the compound of Formula 48 was used as a host of a light-emitting layer, and the material 9 as a dopant of the light-emitting layer: ITO/PEDOT(400 Å)/Formula 48: material 9 (300 Å)/Alq3(40 Å)/LiF(10 Å)/Al (2000 Å). The organic EL devices exhibited blue emission of 3700 cd/m 2 at a voltage of 6V and efficiency of 4.2 cd/A.
From the above Examples, it can be seen that the materials of the present invention have good EL characteristics as phosphorescent and fluorescent materials.
A compound of Formula 1 according to the present invention is available for both dry and wet processes, and has good emission characteristics and thermal stability. Therefore, the use of the compound of the present invention enables to produce an organic EL device having a low driving voltage and good color purity and efficiency.
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Provided are a cyclopentaphenanthrene-based compound and an organic EL device using the same. The cyclopentaphenanthrene-based compound is easy to prepare and excellent in solubility, color purity, and color stability. The cyclopentaphenanthrene-based compound is useful as a material for forming an organic layer, in particular, a light-emitting layer in an organic EL device, and as an organic dye or an electronic material such as a nonlinear optical material.
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This is a continuation of application Ser. No. 855,723, filed Nov. 29, 1977, and now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
An improved process for the manufacture of extended gel free sulfonated elastomeric products includes the formation of a homogeneous mixture of fillers with the acid form of the sulfonated polymer prior to the neutralization of the acid form of the sulfonated polymer with a basic material thereby resulting in a composition having improved physical properties.
2. Description of the Prior Art
This invention relates to a unique and novel improved process for forming extended elastomeric blends of sulfonated elastomeric polymers.
Recently a new class of sulfonated polymers has been described in a number of U.S. Pat. Nos. 3,642,728; 3,836,511; 3,870,841 and 3,847,854, herein incorporated by reference.
U.S. Pat. No. 3,642,728 teaches a method of selective sulfonation with an SO 3 donor of olefinic unsaturation sites of an elastomeric polymer to form an acid form of a sulfonated elastomeric polymer. U.S. Pat. No. 3,642,728 recognized that the free sulfonic acid of the sulfonated elastomer decomposed at conventional rubber processing temperatures and thereby required that a substantial portion of the sulfonic acid be neutralized prior to isolation. It further recognized that optimum thermal stability is reached at total neutralization; however, the melt viscosities of the fully neutralized systems are extremely high. Consequently the fully neutralized systems are extremely difficult, if not impossible, to process in conventional equipment under conventional conditions.
U.S. Pat. No. 3,836,511 teaches an improved method of sulfonation of the olefinic sites of the elastomeric polymer, wherein the improved sulfonating agent is an acyl sulfate. The acid form of the sulfonated elastomeric polymer is neutralized with an organic amine to produce a neutralized sulfonated elastomeric polymer having rather inferior physical properties due to a low degree of ionic association.
The extremely high viscosities of the compositions of U.S. Pat. No. 3,642,728 and the poor physical properties of the compositions of U.S. Pat. No. 3,836,511 limit their usefulness.
U.S. Pat. Nos. 3,870,841 and 3,847,854 teach a method of plasticization of the polymeric backbone of a neutralized sulfonated polymer. The plasticizing agent is incorporated into the sulfonated polymer by hot mixing the neutralized sulfonated polymer with the plasticizing agent. Although, the rheological properties are improved, the incorporation of these plasticizing agents into the neutralized sulfonated polymers is extremely difficult and usually results in a general decrease in physical properties.
The aforementioned patents teach methods of compounding the additives into the neutralized sulfonated elastomeric polymer under high heat and shear conditions or the use of an organic amine neutralizing agent thereby resulting in compositions either having poor rheological or physical properties.
The present invention teaches a new improved process for forming improved compositions of matter which includes forming a homogeneous mixture of an acid form of a sulfonated elastomeric polymer, a mineral or a carbon black filler, and a non-polar process oil, and subsequently neutralizing the sulfonated polymer, wherein the resultant extended elastomeric blends have improved physical properties while maintaining acceptable rheological properties.
SUMMARY OF THE INVENTION
It has been surprisingly found that filled and extended gel-free sulfonated elastomeric products having improved physical and rheological properties can be readily produced by compounding mineral or carbon black fillers and non-polar process oils into a sulfonated elastomeric polymer prior to neutralization. In particular, the acid form of a sulfonated elastomeric polymer is mixed with the appropriate oil extenders and mineral or carbon black fillers under shear such as on a two roll mill until a homogeneous mixture has been achieved. The acid form of the sulfonated elastomeric polymer is then at least partially neutralized with a neutralizing agent. Further neutralization can be achieved during fabrication of the elastomeric product into its final useable form.
GENERAL DESCRIPTION OF THE PRESENT INVENTION
This present unique and novel instant invention relates to an improved process for the manufacture of filled and extended neutralized sulfonated elastomeric polymers, wherein the sulfonated elastomeric polymers are derived from olefinically unsaturated elastomeric polymers. The term "olefinically unsaturated polymer" as used in the specification means polymers both synthetic or natural having in the polymer structure sites of unsaturation whether in the backbone, pendant therefrom or cyclic, except that aromatic containing polymers are excluded from this description.
In particular, unsaturated polymers of this invention include low unsaturation polymers having about 0.1 to about 10 mole percent olefinic unsaturation such as Butyl rubber, halogenated Butyl rubbers, or EPDM terpolymers. Additionally, other unsaturated polymers contemplated are: partially hydrogenated polyisoprenes, partially hydrogenated polybutadienes, isoprene-styrene copolymers, and butadiene-styrene copolymers.
The expression "Butyl rubber" as employed in the specification and claims is intended to include copolymers made from a polymerization reaction mixture having therein from 70 to 99.5% by weight of an isoolefin which has about 4 to 7 carbon atoms, e.g. isobutylene and about 0.5 to 30% by weight of a conjugated multiolefin having from about 4 to 14 carbon atoms, e.g. isoprene. The resulting copolymer contains 85 to 99.8% by weight of combined isoolefin and 0.2 to 15% of combined multiolefin.
Butyl rubber generally has a Staudinger molecular weight of about 20,000 to about 500,000, preferably about 25,000 to about 400,000 especially about 100,000 to about 400,000, and a Wijs Iodine No. of about 0.5 to 50, preferably 1 to 15. The preparation of Butyl rubber is described in U.S. Pat. No. 2,356,128 which is incorporated herein by reference.
For the purposes of this invention, the Butyl rubber may have incorporated therein from about 0.2 to 10% of combined multiolefin; preferably about 0.5 to about 6%; more preferably about 1 to about 4%, e.g. 2%.
Illustrative of such a Butyl rubber is Exxon Butyl 365 (Exxon Chemical Co.), having a mole percent unsaturation of about 2.0% and a Mooney viscosity (ML, 1+8, 212° F.) of about 40-50.
Halogenated Butyl rubber is available commercially and is prepared through the halogenation of Butyl rubber in solution. The preparation of halogenated Butyl rubber is described in U.S. Pat. No. 3,099,644 which is incorporated herein by reference.
Illustrative of a halogenated Butyl rubber is Exxon Chlorobutyl 1066, a chlorinated Butyl rubber containing about 1.3 wt. % chlorine, having about 1.7 mole percent unsaturation, and a viscosity average molecular weight of about 357,000.
Low molecular weight Butyl rubbers, i.e. Butyl rubbers having a viscosity average molecular weight of about 5,000 to 85,000 and a mole percent unsaturation of about 3 to about 4% may be sulfonated by the process of this invention. Preferably, these polymers have a viscosity average molecular weight of about 25,000 to about 60,000.
The EPDM terpolymers are low unsaturated polymers having about 1 to about 10.0 wt. % olefinic unsaturation, more preferably about 2 to about 8, most preferably about 3 to 7, defined according to the definition as found in ASTM-D-1418-64 and is intended to mean a terpolymer containing ethylene and propylene in the backbone and a diene in the side chain. Illustrative methods for producing these terpolymers are found in U.S. Pat. No. 3,280,082, and French Pat. No. 1,386,600, which are incorporated herein by reference. The preferred terpolymers contain about 40 to 75 wt. % ethylene and about 1 to about 10 wt. % of a diene monomer, the balance of the polymer being propylene. Preferably, the polymer contains about 50 to about 70 wt. % ethylene, e.g. 50 wt. % and about 2.6 to about 9.0 wt. % diene monomer, e.g. 5.0 wt. %. The diene monomer is preferably a nonconjugated diene. The Mn of the terpolymer is preferably about 10,000 to about 200,000; more preferably, about 15,000 to about 100,000; and most preferably about 20,000 to about 60,000. The Mooney viscosity (ML, 1+8, 212° F.) of the terpolymer is preferably about 5 to about 60, more preferably about 10 to about 50 and most preferably about 15 to about 40. The Mv of the EPDM is preferably below about 350,000 and more preferably below about 500,000 and more preferably below about 350,000.
Illustrative of these nonconjugated diene monomers which may be used in the EPDM terpolymer are 1,4-hexadiene, dicyclopentadiene, 5-ethylidene-2-norbornene, 5-methylene-2-norbornene, 5-propenyl-2-norbornene and methyl tetrahydroindene.
A typical EPDM is Vistalon 2504 (Exxon Chemical Co.) a terpolymer having a Mooney viscosity (ML, 1+8, 212° F.) of about 40 and having 50 wt. % of ethylene, 45 wt. % of propylene and 5.0 wt. % of 5-ethylidene-2-norbornene with an Mn of about 47,000, an Mv of about 145,000 and an Mw of about 174,000.
Vistalon 3708 (Exxon Chemical Co.) is a terpolymer having a Mooney viscosity (ML, 1+8, 260° F.) of about 45-55 and having about 64 wt. % of ethylene, about 3.3 wt. % of 5-ethylidene-2-norbornene, and about 32.7 wt. % of propylene with an Mn of about 53,000, an Mn of about 343,000 and an Mv of about 270,000.
Vistalon 6505 (Exxon Chemical Co.) is a terpolymer having a Mooney viscosity (ML, 1+8, 260° F.) of about 45-55 and having about 53 wt. % of ethylene, about 9.0 wt. % of 5-ethylidene-2-norbornene and about 38 wt. % of propylene.
Other EPDM terpolymers Vistalon 2504-20 and Vistalon 6505-20 are derived from Vistalon 2504 and Vistalon 6505 by a controlled extrusion process, wherein the resultant Mooney viscosity at 212° F. is about 20. The Mn of Vistalon 2504-20 is about 26,000, the Mv is about 90,000 and the Mw is about 125,000.
Nordel 1320 (DuPont) is another EPDM terpolymer having a Mooney viscosity at 212° F. of about 25 and having about 53 wt. % of ethylene, about 3.5 wt. % of 1,4-hexadiene, and about 43.5 wt. % of propylene.
In carrying out the present invention, an olefinically unsaturated polymer is sulfonated with a sulfonating agent selected from an acyl sulfate, a mixture of sulfuric acid and an acid anhydride or a sulfur trioxide donor complexed with a Lewis base containing oxygen, nitrogen, or phosphorous.
The term "sulfur trioxide donor" as used in the specification means a compound containing available sulfur trioxide. Illustrative of such sulfur trioxide donors are SO 3 , chlorosulfonic acid, fluorosulfonic acid, sulfuric acid, oleum, etc. The term "complexing agent" as used in the specification means a Lewis base suitable for use in the practice of this invention, wherein a Lewis base is an electron pair donor. Typical Lewis bases are: dioxane, tetrahydrofuran, tetrahydrothiophene or triethyl phosphate.
The molar ratio of SO 3 donor to complexing agent may be as high as 15 to 1; preferably less than about 9:1; more preferably about 4:1 to about 1:1, e.g. 2:1.
The preferred solvents for preparation of the complexes of sulfur trioxide donor with complexing agents are chlorinated hydrocarbons. Illustrative of such chlorinated solvents are carbon tetrachloride, dichloroethane, chloroform, and methylene chloride. The complexes may also be prepared by direct addition of reagents if precautions are taken to dissipate evolved heat.
The reactions of ethereal complexes of SO 3 with the unsaturation of polymer chains has been found to be nonquantitative generally because they are consumed through side reactions with impurities such as water. Therefore, the use of excess complex is desirable to give the required amount of sulfonation.
Other suitable sulfonating agents are the acyl sulfates, which are selected from the group of acetyl, propionyl, butyryl, or benzoyl sulfate, in particular acetyl sulfate. The acyl sulfate may be produced by reacting concentrated sulfuric acid with an acid anhydride or an acid halide in the presence or the absence of a solvent. For example, acetic anhydride may be reacted with sulfuric acid to form acetyl sulfate which may be used to sulfonate the polymers of this invention. If desired, acetic anhydride may be added to a solution of the polymer in a suitable solvent and sulfuric acid subsequently added to form acetyl sulfate in situ. Alternatively, acetyl sulfate may be preformed by reaction of sulfur trioxide with acetic acid in a non-reactive solvent.
It should be pointed out that neither the sulfonating agent nor the manner of sulfonation is critical, provided that the sulfonating method does not degrade the polymer backbone.
In the practice of this invention, the polymer to be sulfonated is dissolved in a suitable solvent and reacted with the sulfonating agent. The solvent medium must be a neutral one for the rubber and the sulfonating agent. The solvent is preferably an aromatic hydrocarbon, an aliphatic hydrocarbon, a cycloaliphatic hydrocarbon or a halogenated aromatic hydrocarbon. Illustrations of these solvents are: isopentane, pentane, cyclohexane, isohexane, hexane, heptane and homologues thereof, benzene, toluene, chlorobenzene or xylene. The preferred solvent is an aliphatic hydrocarbon.
Sulfonation of the polymer is conducted at a temperature between -100° C. and +100° C. Sulfonation occurs when the sulfonating agent is added to the polymer solution. The sulfonating agent is dissolved in a suitable solvent, or may be added directly without solvent. With acetyl sulfate reagent it is most preferred to add acetic anhydride to the polymer cement and then sulfuric acid to prepare the acetyl sulfate reagent in situ. Reaction time may be about 1 to about 60 minutes, more preferably about 5 to about 45 and most preferably about 15 to about 30, wherein the product remains soluble throughout the reaction period.
The acid form of the sulfonated elastomeric is quenched with water, or a liquid aliphatic alcohol such as methanol, ethanol or isopropanol, an aromatic hydroxyl compound such as phenol, or a cycloaliphatic alcohol such as cyclohexanol. The product can most easily be recovered by flashing off the solvent in hot water, wherein the water also decomposes the unreacted sulfonating agent. The product may also be recovered by evaporation of the solvent by a suitable means.
The wet crumb is thoroughly washed with water to remove soluble reagent components, such as sulfuric acid, acetic acid, and tetrahydrofuran, and low molecular weight, water-soluble sulfonic acids which derive from the reagent components, such as sulfoacetic acid. Washing improves tthe stability of the polymeric sulfonic acid and reduces the corrosiveness of the wet crumb. The water content of the screened and drained wet crumb is generally about 50 wt. % to about 80 wt. % depending upon the size of the crumb and conditions of operation. The water content of the steam stripped polymer may be reduced through washing with low boiling ketones or alcohols, such as acetone and methanol, although this is neither necessary nor preferred.
After thorough washing of the crumb of the polymeric sulfonic acid the crumb is mechanically dewatered at a temperature below about 150° F. This is readily accomplished with a variety of commercial equipment such as a two-roll mill, a dewatering extruder, an expeller, a filter press, a rotary drum filter, a Reitz V-press, and a centrifuge. Combinations of such equipment can be used to reduce the water content of the polymeric sulfonic to the desired level. It is desirable to lower the water level of the elastomeric sulfonic acid to less than about 15 wt. %, preferably less than about 10 wt. %, and most preferably less than about 5 wt. %. These lower levels of water are easily achieved through a combination of mechanical, shearing, and thermal effects.
The elastomeric sulfonated polymer is formulated and mixed with a combination of fillers, extender oils and additives, and appropriate bases are added during or after the mixing step to effect at least partial neutralization of the sulfonic acid. During this compounding step the shearing required to mix the components and the temperature developed as a result of this shearing action result in further loss of moisture. Complete neutralization of the formulation is achieved during fabrication such as a molding or extrusion process at elevated temperature into a useful end product. The molded or extruded article is essentially totally free of moisture at the end of the molding or extrusion cycles. In cases where the formulated and fully neutralized product has sufficiently low melt viscosity for refabrication, the formulated product can be extruded and pelletized, and the resultant pellets can be further dried if necessary to achieve the desired level of moisture.
The elastomeric polymeric acid is soluble in a variety of solvent combinations, for example, toluene with a minor amount of methanol. This solubility demonstrates that sulfonation has occurred without crosslinking. The sulfonic acid-containing polymers have improved physical properties over those of the unsulfonated polymers which is attributable to the hydrogen bonding of the sulfonic acid groups.
The amount of desirable sulfonation depends on the particular application. Preferably, the elastomeric polymer is sulfonated at about 10 to about 60 meq. SO 3 H/100 g of polymer, more preferably at about 15 to about 50 meq. SO 3 H/100 g of polymer and most preferably at about 20 to about 40 meq. SO 3 H/100 g. of polymer. The sulfonic acid content can be determined by either titration of the polymeric sulfonic acid or Dietert Sulfur analysis. In the titration of the sulfonic acid the polymer is dissolved in solvent consisting of 95 parts of toluene and 5 parts of methanol at a concentration level of 50 grams per liter of solvent. The acid form is titrated with ethanolic sodium hydroxide to an Alizarin Thymolphthalein endpoint.
The acid form of the sulfonated polymer is gel-free and hydrolytically stable. Percent gel is measured by stirring the sulfonated polymer in a solvent comprised of 95 vol. % toluene/5 vol. % methanol at a concentration of 5 wt. %, for 24 hours, allowing the mixture to settle, withdrawing a weighed sample of the supernatant solution and evaporating to dryness.
Hydrolytically stable means that the acid function, in this case the sulfonic acid, will not be eliminated under hydrolytic conditions to a neutral moiety which is incapable of being converted to a highly ionic functionality.
As described in U.S. Pat. No. 3,642,728, herein incorporated by reference, the free polymeric sulfonic acid suffers from thermal instability. In addition the physical properties of the free polymeric acid are not very good. Although the polymeric sulfonic acid has improved properties over the unsulfonated elastomer as a result of relatively weak interactions between the sulfonic acid groups these properties are generally unsatisfactory and insufficient for most applications. Strong ionic interactions leading to thermal stability and markedly improved physical properties are achieved only through neutralization of the sulfonic acid to form the corresponding metal or ammonium salt. The free acid has poor physical properties because of the weak sulfonic acid interactions but as a consequence possesses low melt viscosity and thereby good processability. The high ionic interactions in the salt have the inverse effect, i.e. good physical properties on the one hand and high melt viscosity and poor processability on the other.
The neutralizing agents of the present invention are basic salts of carboxylic acids, wherein the cation of the basic salt is selected from the group consisting of ammonium, aluminum, lead, iron, antimony or Groups IA, IIA, IB or IIB of the Periodic Table of Elements and mixtures thereof. Suitable monovalent metal ions are Na, K, Li, Cs, Ag, Hg, and Cu. Suitable divalent metal ions are Be, Mg, Ca, Sr, Ba, Cu, Cd, Hg, Sn, Fe, Pb, Co, Ni and Zn. Most preferred are zinc, magnesium, barium, sodium and lead. In preparing the ionomer the neutralizing agent is added at levels at least about 100% of stoichiometry and preferably in excess of stoichiometry.
The carboxylate ion of the metallic salt is derived from the following carboxylic acids as illustrated in the present invention; however, other carboxylic acids of the same generic class can be readily employed and are considered within the spirit and scope of the present embodiment. These carboxylic acids are: acetic, benzoic, lauric, palmitic, myristic, decanoic, octanoic, and stearic.
When neutralization is effected with a metal carboxylate a product of the neutralization is the corresponding carboxylic acid.
--SO.sub.3 H+R--COOM→--SO.sub.3 M+RCOOH
Although the degree of efficacy varies with structure and composition, carboxylic acids are in fact ionic plasticizers, i.e. they relax ionic associations thereby decreasing apparent molecular weight, lowering melt viscosity, and improving melt processability. Low molecular weight carboxylic acids, such as acetic acid, are not very effective ionic plasticizers at low concentration and are volatile so that they are substantially lost during compounding, extrusion, and other processing steps. Thus when neutralization of the sulfonic acid is effected with a lower molecular weight metal carboxylate the resultant metal sulfonate is unplasticized resulting in a very strong ionic association, high apparent molecular weight, high melt viscosity, and poor melt processability. This result is no different than if the sulfonated polymer were neutralized in solution immediately after sulfonation. An advantage of this invention is that formulations can be fully and homogeneously mixed prior to neutralization of the polymeric sulfonic acid thereby permitting the preparation of formulations that could not have been prepared otherwise.
The higher molecular weight carboxylic acids are not volatile and remain with the neutralized gum. Because of their constitution the higher molecular weight carboxylic acids, such as lauric, palmitic, myristic, stearic, arachidic, and behenic, are excellent flow improvers, i.e. at processing temperatures viscosities are significantly reduced and flow stability is markedly improved. Thus when neutralization of the sulfonic acid is effected with a high molecular weight metal carboxylate it is accompanied by the generation of a non-volatile ionic domain plasticizer. Thus the melt viscosity of the formulation is improved through plasticizer generation. The carboxylic acid, however, has a deleterious effect upon physical properties, especially at elevated temperatures, for example 70° C.
Polyvalent cations, the most important of which are the divalent cations, such as zinc, magnesium and barium must be used in some excess of stoichiometry because it is not possible for all sulfonic acids to be neutralized with simply an equivalent amount of divalent cation. Consequently not only are disulfonate linkages, --SO 3 --M--O 3 S--, formed but also monosulfonate linkages, --SO 3 --M--OOC--R. The relative amounts of these moieties and the type of carboxylate substituent exert a substantial effect upon both melt processability and physical properties.
Some of the higher molecular weight metal carboxylates can themselves act as effective ionic domain plasticizers for the neutralized systems when present in sufficient quantity, for example 10 parts to 30 parts per 100 of unplasticized neutralized gum. This is especially true of zinc carboxylate, such as zinc stearate, which not only functions to improve melt flow but imparts remarkable improvements on tensile properties at room temperature and at elevated temperatures. Most metal carboxylates possess little effect upon the ambient temperature tensile properties of neutralized gums and a significantly poorer effect upon melt processability than zinc stearate. As a consequence a high degree of ionic association occurs at higher temperatures.
As a consequence of the effects of higher molecular weight carboxylic acids and metal carboxylates it is possible to modulate both the melt viscosity and the physical properties of the neutralized gum not only through changes in concentration of the metal carboxylate but also through the use of mixtures in different metal carboxylates. It is further possible to modulate flow and physical properties by the conversion of the generated carboxylic acids to the corresponding metal carboxylates by reaction with the corresponding metal oxides and hydroxides.
--SO.sub.3 H+MO or (MOH)→--SO.sub.3 M+H.sub.2 O
Such a conversion of carboxylic acids to metal carboxylates has been described in U.S. Pat. No. 4,014,831, herein incorporated by reference. The metallic hydroxides are selected from Groups IA and IIA of the Periodic Table of Elements and mixtures thereof. Useful examples of metal hydroxides are NaOH, KOH, LiOH, Mg(OH) 2 and Ba(OH) 2 . The metallic oxides are selected from the group consisting essentially of Groups IIA, IIB or lead and mixtures thereof of the Periodic Table of Elements. Illustrative examples are MgO, CaO, BaO, ZnO, PbO 2 , or Pb 3 O 4 and mixtures thereof. Especially preferred are the oxides of zinc and lead.
Neutralization of the polymeric sulfonic acid can be effected with metallic oxides alone, wherein the metallic ion is selected from the group consisting essentially of Groups IIA, IIB or lead and mixtures thereof of the Periodic Table of Elements. Illustrative examples are MgO, CaO, BaO, ZnO, PbO 2 or Pb 3 O 4 and mixtures thereof.
Other neutralizing agents which can be used alone are basic salts of hydroxides, alkoxides, or alkanoates, wherein the cation is selected from Groups IA or IIA of the Periodic Table of Elements and mixtures thereof. Useful examples of metal hydroxides are NaOH, KOH, LiOH, Mg(OH) 2 and Ba(OH) 2 .
The improved process of the present invention comprises the steps of isolation of the acid form of the sulfonated elastomeric polymer having less than 15% retained water. The acid form is mixed at a temperature of less than about 150° F. with appropriate amounts of fillers, extender oils and other additives until a homogeneous mixture has been achieved. A neutralizing agent is added to the homogeneous mixture at a level at least 100% of stoichiometry and mixing is continued until homogenity is achieved and at least partial neutralization of the acid form has been realized. Complete neutralization of the acid form can be realized in finishing operations such as extrusion and pelletization and in fabrication operations such as injection molding, extrusion, or compression molding.
The ionic associations of acid form of the sulfonated elastomeric polymer are minimal as compared to a neutralized sulfonated elastomeric polymer which cannot be easily processed due to its high ionic association. When the fillers and oils are mixed with the sulfonated elastomeric polymer before neutralization, improved dispersion is realized due to the mobility of the elastomeric polymer molecules and its minimal ionic associations. This improved dispersion results in a sulfonated elastomeric product having improved physical and rheological properties. The fillers and oils are mixed into the acid form at temperatures below 150° F. in order to avoid decomposition of the acid form during processing. After sulfonation, isolation, and drying of the polymeric free sulfonic acid said product is converted to an ionomer by reaction with at least about 100% of the stoichiometric proportion of a metallic or nitrogen base, based on the sulfonic acid content of said sulfonated polymer.
Fillers which can be used in the present invention are mineral fillers and carbon blacks. The mineral fillers employed are selected from talcs, ground calcium carbonate, water precipitated calcium carbonate, or delaminated, calcined or hydrated clays and mixtures thereof. Typically, these mineral fillers have a particle size of about 0.03 to about 20 microns, more preferably about 0.3 to about 10, and most preferably about 0.5 to about 10 . The oil absorption as measured by grams of oil absorbed by 100 grams of filler is about 10 to about 100, more preferably about 10 to about 85 and most preferably about 10 to about 75. Typical mineral fillers employed in this invention are illustrated in Table I.
Carbon blacks range widely in physical and chemical properties. Physically they vary in average particle size, particle size distribution, specific surface area, porosity of surface, and the tendency of the individual primary particles to be associated in chain-like structure. Chemically they vary in the population and nature of oxygenated structures combined with their surface. Typical carbon blacks employed by this invention are illustrated in Table II.
These mineral and carbon black fillers are blended into the blend composition at about 5 to about 300 parts per hundred; more preferably at about 20 to about 250; and most preferably at about 25 to about 200.
TABLE I__________________________________________________________________________ Oil Absorption grams of oil/ Specific Avg. ParticleFiller Code # 100 grams of filler Gravity Size Micron pH__________________________________________________________________________Calcium carbonateground Atomite 15 2.71 9.3Calcium carbonateprecipitated Purecal U 35 2.65 .03-.04 9.3Delaminated clay Polyfil XB 30 2.61 4.5 6.5-7.5Hydrated clay Suprex 2.6 2 4.0Calcined clay Icecap K 50-55 2.63 1 5.0-6.0Magnesium silicate(talc) Mistron Vapor 60-70 2.75 2 9.0-7.5__________________________________________________________________________
TABLE II__________________________________________________________________________ EM Nigrometer Sp. Surface Diameter Volume, Total Acids,Carbon Black Type Index Area, m.sup.2 /g (d.sub.n), A° % pH meq./g__________________________________________________________________________Black Pearls 46 Channel 65 800 130 14.0 3.0 2.42Black Pearls 74 Channel 74 332 170 5.0 5.0 0.95Spheron 9 Channel 85 105 290 5.0 5.0 0.94Vulcan 9 Oil Furnace 86 124 200 1.5 8.5 0.84 (SAF)Vulcan 3 Oil Furnace 90 74 290 1.0 8.5 0.68 (HAF)Regal 330 Low Structure 84.5 -- 240 -- 8.5 0.42 Oil FurnaceSterling S Gas Furnace 99 23 800 1.0 9.5 0.18Sterling FT Thermal (FT) 107 13 1800 0.5 8.5 0.12Sterling MT Thermal (MT) 110 6 4700 0.5 8.5 0.10__________________________________________________________________________
The oils employed in the present invention are non-polar process oils having less than about 6 wt. % polar type compounds as measured by molecular type clay gel analysis. These oils are selected from paraffinics ASTM Type 104B as defined in ASTM-D-2226-70, aromatics ASTM Type 102 or naphthenics ASTM Type 104A, wherein the oil has a flash point by the Cleveland open cup of at least 350° F., a pour point of less than 40° F., a viscosity of about 70 to about 3000 ssu at 100° F. and a number average molecular weight of about 300 to about 1,000, and more preferably about 300 to 750. The preferred process oils are paraffinics. Table III illustrates typical oils encompassed by the scope of this invention.
The oils are incorporated into the blend composition at a concentration level of about 20 to about 200 parts per hundred; more preferably at about 20 to about 175, and most preferably at about 25 to about 150.
TABLE III______________________________________ Vis- % % % cosity Po- Aro- Satu-Type Oil Oil Code # ssu Mn lars matic rates______________________________________Paraffinic Sunpar 115 155 400 0.3 12.7 87.0Paraffinic Sunpar 180 750 570 0.7 17.0 82.3Paraffinic Sunpar 2280 2907 720 1.5 22.0 76.5Aromatic Flexon 340 120 -- 1.3 70.3 28.4Naphthenic Flexon 765 505 -- 0.9 20.8 78.3Aromatic Sundex 790 3000 -- 5.4 59.3 35.3Naphthenic Sunthene 4240 2206 -- 1.1 43.9 55.0______________________________________
Various other additives can be incorporated into the blend composition to improve the physical properties, the appearance, the chemical properties of the formed elastomeric article or to modify the processability of the blend compositions.
A crystalline polyolefinic thermoplastic can be incorporated into the blend composition in minor proportions as a means for modification of the rheological properties of the blend compositions as well as the stiffness of the elastomeric article. Typically, the crystalline polyolefinic thermoplastic is added to the blend composition at a concentration level of about 0 to about 100 parts per hundred by weight based on 100 parts of sulfonated polymer, more preferably at about 0 to about 75; and most preferably at about 0 to about 50.
A lubricant can be employed in the blend composition at a concentration level of less than about 20 parts per hundred based on 100 parts of the neutralized sulfonated elastomeric polymers, and more preferably less than about 15. The lubricants of the present instant invention are non-polar paraffinic hydrocarbon waxes having a softening point of about 125° F. to about 220° F., more preferably 150° F. to 200° F., wherein the wax has a number average molecular weight of about 300 to about 4000, more preferably 300 to 3000 and less than about 2 wt. % polar constituents. These lubricants modify the rheological properties of the composition, improve the processability in forming the elastomeric article and impart a shine or gloss to the elastomeric article. Additionally, amorphous polypropylene can be used as a lubricant.
Additionally, mineral reinforcing fillers can be added as additives to the blends of sulfonated polymer, filler and oil, wherein the reinforcing filler is selected from the group consisting essentially of silica, or calcium silicate and mixtures thereof. These reinforcing agents are generally characterized as having particle sizes below 0.1 microns and oil absorption above about 100. These reinforcing fillers are incorporated in the blend composition at about 0 to 50 parts per hundred based on 100 parts of sulfonated polymer, more preferably 0 to 25.
The ingredients incorporated into the blend compositions of the present invention, in conjunction with the type of elastomeric polymer, the degree of sulfonation, and the metal counterion of the neutralized sulfonated elastomeric polymer give materials processable by extrusion or injection molding processes into elastomeric articles having the desirable physical and rheological properties. These combined physical properties and rheological processability characteristics were not previously obtainable in the aforementioned U.S. patents.
Conversion of the uncompounded or compounded polymeric sulfonic acid by means of a metallic base or carboxylate occurs readily even at room temperature although higher temperatures, for example 75° C. to 200° C., most preferably 100° C. to 150° C. and high shear mixing may be required to get complete neutralization. Sufficient mixing and heat are normally obtained under conventional mixing conditions with equipment such as rubber mills, Banbury mixers, and extruders. The resultant neutralized compounds have excellent processability for extrusion, injection molding, vacuum forming, compression molding and similar operations.
A means of characterizing the apparent molecular weight of a polymer involves the use of melt rheological measurements. For ionic polymers, this is the preferred method since solution techniques are difficult to interpret due to the complex nature of the ionic associations. Melt rheological measurements of apparent viscosity at a controlled temperature and shear rate can be used as a measure of apparent molecular weight of an ionic polymer. Although the exact relationship between melt viscosity and apparent molecular weight for these ionic systems is not known, for the purposes of this application the relationship will be assumed to be one of direct proportionality. Thus, in comparing two materials, the one with the higher melt viscosity will be associated with the higher apparent molecular weight.
The melt viscosity of the systems investigated were determined by the use of an Instron Capillary Rheometer. Generally, the melt viscosity measurements were made at a temperature of 200° C. and at various shear rates corresponding to crosshead speeds from 0.005 in/min to 20 in/min. The apparent viscosity of 200° C. and at a shear rate of 0.73 sec -1 (0.005 in/min) will be employed as a characterization parameter in this application. A measure of the melt elasticity of a given system can also be obtained from these rheological measurements. A type of flow instability known as melt fracture is exhibited by many polymeric materials of high molecular weight. This phenomenon is shear sensitive and thus will generally exhibit itself at a given shear rate and temperature. The shear rate for the onset of melt fracture indicates the upper shear rate for processing a given material.
DETAILED DESCRIPTION
The advantages of the improved process of manufacturing these new compositions of sulfonated elastomeric products may be more readily appreciated by reference to the following examples.
EXAMPLE 1
A commercial EPDM rubber, Vistalon 2504, which is a terpolymer of ethylene, propylene and 5-ethylidene-2-norbornene having an Mn of about 46,700, an Mv of about 145,000 and a Mooney viscosity (ML, 1+8, 212° F.) of about 40, was sulfonated according to the following procedure. 500 grams of Vistalon 2504 was dissolved in 5.0 liters of hexane and 28.7 ml of acetic anhydride to form a cement. Concentrated sulfuric acid (10.52 ml) was dripped slowly into the cement, and the cement was stirred for 30 minutes at room temperature. The reaction was quenched after thirty minutes with 200 ml of isopropanol containing 2.5 grams of Antioxidant 2246 [2,2'-methylene-bis-(4-methyl-6-tert butylphenol)]. The cement was steam stripped then to isolate the acid form of the sulfonated elastomeric polymer, and the acid form was then washed with water in a Waring blender. The resultant crumb was dewatered to less than 10 wt. % water on a two-roll rubber mill at about 110° F. It contained 0.98 wt. % sulfur.
Samples of the acid form of the sulfonated EPDM polymer were placed in vacuum ovens at 80° C. and 100° C. and analyzed after 24 and 72 hours with the results shown in Table IV.
TABLE IV______________________________________ Sulfur Content, wt. % Based on Sulfonated EPDM Rubber______________________________________At 176° F.24 hours 1.0072 hours 0.92At 212° F.24 hours 0.7872 hours 0.64______________________________________
This example shows that the acid form of a sulfonated EPDM polymer is thermally labile and that care must be exercised in its handling. However, these results show that little degradation occurs at about 176° F. Consequently little degradation, and therefore no deleterious effects, are encountered when the polymeric sulfonic acid is processed for relatively short periods of time at below about 150° F.
EXAMPLE 2
To a solution of 200 grams of Vistalon 2504 in 4 liters of chlorobenzene was added 50 ml. of 1.0 molar acetyl sulfate in chlorobenzene. The acetyl sulfate was prepared by mixing 4.0 moles of acetic anhydride with 1.0 mole of concentrated sulfuric acid at below 10° C. in 566 ml of chlorobenzene. The cement was stirred for thirty minutes and the reaction was quenched with 100 ml of methanol containing 1.0 gram of Antioxidant 2246. The reaction mixture was steam stripped, the product pulverized with water in a Waring blender, and the resultant wet crumb dewatered on a rubber mill at about 110° F. to form the acid form of the sulfonated EPDM polymer which contained 20.6 meq. of SO 3 H groups per 100 grams of the sulfonated EPDM polymer as measured by acid titration.
Samples of the acid form of the sulfonated EPDM terpolymer were mixed on a cold rubber mill at a temperature of less than about 150° F. for a period of time sufficient to form a homogeneous mixture with sodium stearate, zinc stearate, magnesium stearate, calcium stearate, and barium stearate, wherein 11 parts of the metal stearate was used per 100 parts of the sulfonated terpolymer. The formulated gums were compression molded for various times at various temperatures. Excellent flawless micropads were obtained in all cases which exhibited excellent tensile properties as shown in Table V. The control in this Table is the acid form of the sulfonated EPDM polymer.
TABLE V__________________________________________________________________________ Mold 300% Tensile Elongation, Tensile VolumeMetal Stearate Min/°F. Modulus, psi Strength, psi % Set, % Swell, %__________________________________________________________________________Control 60/350 70 210 990 77 --Sodium Stearate 15/285 400 1540 590 -- -- 60/350 440 2770 620 12.5 510 5/400 450 2640 645 -- --Zinc Stearate 60/350 310 1590 660 18.7 690Magnesium Stearate 60/350 500 3200 700 18.7 330Calcium Stearate 60/350 450 2260 635 12.5 470Barium Stearate 15/285 490 1310 500 -- -- 60/350 460 1720 560 -- -- 5/400 480 1880 610 -- --__________________________________________________________________________
This example clearly demonstrates that the acid form of the sulfonated EPDM polymer can be readily isolated and dewatered. Flawless articles can be prepared through the mixing of the acid form of the sulfonated EPDM polymer on the cold two roll rubber mill with a metallic salt of a carboxylic acid to at least partially neutralize the acid form and subsequently compression molding the product at an elevated temperature thereby causing complete neutralization of the acid form. The particular metallic ion used to neutralize the acid form has a dramatic effect on the tensile properties of the neutralized, ionically cross-linked sulfonated EPDM elastomeric product.
EXAMPLE 3
To a solution of 400 grams of Vistalon 2504 dissolved in 8000 ml. of chlorobenzene was dripped in 160 ml. of a 1 Molar acetyl sulfate solution prepared according to the process of Example 2. After 30 minutes stirring of the cement at room temperature, the reaction was terminated by the addition of 160 ml. of methanol containing 1.6 grams of Antioxidant 2246. The reaction mixture was steam stripped, the product was pulverized twice in methanol containing Antioxidant 2246 in a Waring blender; the resultant crumb of the acid form of the sulfonated EPDM rubber was dewatered on a two-roll rubber mill until the material was lacy and then the material was washed twice again wih stabilized methanol. The crumb was dewatered again and banded on a warm rubber mill at about 140° F. Sulfur analysis showed the acid form of the sulfonated EPDM polymer to contain about 26.6 meq. SO 3 H groups per 100 grams of polymer.
A sample of the sulfonated EPDM was mixed on a cold two-roll rubber mill with 16 phr of magnesium stearate. The formulation was then heated at 325° F. for 45 minutes.
Another sample of the acid form of the sulfonated EPDM polymer (40 grams) was dissolved in 760 ml. of toluene and 40 ml. methanol. To the solution was added 23.3 ml. of 1 N magnesium acetate in 50 ml. water/50 ml. methanol. The neutralized product was steam stripped, washed twice with stabilized methanol in a Waring blender, and dried in a vacuum oven.
A compression molded sample of the bulk neutralized magnesium stearate was smooth and shiny. The solution neutralized sample of magnesium acetate could not be compression molded to a smooth, strain free pad.
The rheologies of these two neutralized samples were measured on an Instron Capillary Rheometer using a 0.05"×1.0" die at 200° C. The shear rate-shear stress and viscosity data of these two samples are summarized in Table VI. A compression molded slab at 325° F. for 45 minutes was prepared for the magnesium stearate sample for testing. The dried crumb of the magnesium acetate was used. The magnesium acetate sample gave rough strands below 15 sec -1 and at higher shear rates the strands disintegrated into crumb. This behavior is indicative of a cross-linked elastomer. The magnesium stearate sample showed a dramatic change in the flow and melt structure. Substantially lower viscosities and a delay in melt fracture was obtained with the magnesium stearate sample which indicates an improvement in processability.
TABLE VI__________________________________________________________________________Shear Rate 0.74 sec.sup.-1 7.4 sec.sup.-1 74 sec.sup.-1 Comments__________________________________________________________________________Mg Acetate, SolutionNeutralizedShear Stress, Dynes/cm.sup.2 × 10.sup.-5 50.0 67.0 75.7 Strand does not holdViscosity, poise × 10.sup.-5 67 9.0 1.0 at 15 sec.sup.-1. Severe crumbling at 74 sec.sup.-1.Mg Stearate, BulkNeutralizedShear Stress, Dynes/cm.sup.2 × 10.sup.-5 20.1 42.6 68.6 Melt fracture at 30Viscosity, poise × 10.sup.-5 27 5.7 0.92 sec.sup.-1. Maintains strand integrity beyond 300 sec.sup.-1.__________________________________________________________________________
EXAMPLE 4
A sulfonated EPDM polymer of Vistalon 2504 was prepared according to the procedure of Examples 2 and 3. The sulfonated EPDM polymer contained 17.8 meq. of SO 3 H groups per 100 grams of polymer.
Sample A was prepared by mixing 100 grams of polymer with 11 grams of magnesium stearate on a cold two-roll mill.
Sample B was prepared by mixing 100 grams of polymer with 11 grams of barium stearate on a cold two-roll mill.
Samples C and D were prepared by mixing 100 grams of polymer with 50 grams of HAF carbon black on a cold two-roll mill. After a homogeneous mixture had been obtained, for each sample, 11 grams of either magnesium stearate or barium stearate was added to make respectively Samples C and D. The mixing was continued on the mill to give at least partially neutralized samples of the sulfonated EPDM polymer.
Samples E and F were prepared by mixing 100 grams of the polymer with 75 grams of carbon black SRF, 75 grams of carbon black FEF, and 100 grams of Flexon 845 oil on a cold two-roll mill. After a homogeneous mixture had been obtained for each, 11 grams of either magnesium stearate or barium stearate was added to make respectively Samples E and F. The mixing was continued on the mill to give at least partially neutralized samples of the sulfonated EPDM polymer. The six samples (A-F) were compression molded at 325° F. for 45 minutes. The resultant samples were smooth and shiny. The tensile properties of these neutralized samples are summarized in Table VII and the rheological properties of the six samples are summarized in Table VIII. Excellent physical and rheological properties are obtained even with highly filled systems.
TABLE VII__________________________________________________________________________ At Room Temperature At 100° C. 300 Tensile 300 Tensile Metal Modulus, Strength, Elong., Modulus, Strength, Elong.,Sample Formulation Stearate psi psi % psi psi %__________________________________________________________________________A Gum Magnesium 370 3010 600 140 270 745B Gum Barium 410 2340 610 120 160 630C Black Magnesium 1450 2600 560 500 600 445D Black Barium 1460 2380 510 475 550 390E Oil-Black Magnesium 355 340 290 -- 100 140F Oil-Black Barium 610 720 420 -- 210 270__________________________________________________________________________
TABLE VIII__________________________________________________________________________ Shear Stress Viscosity, Shear RateSample Metal Ion Shear Rate, Sec.sup.-1 Dynes/cm.sup.2 × 10.sup.-5 Poise At Fracture__________________________________________________________________________A Mg 0.74 17.7 2.4 × 10.sup.6 7.4 sec.sup.-1 7.4 43.0 5.8 × 10.sup.5 74 62.3 8.4 × 10.sup.4B Ba 0.74 32.8 4.4 × 10.sup.6 0.74 sec.sup.-1 7.4 54.2 7.3 × 10.sup.5 74 73.3 9.9 × 10.sup.4C Mg 0.74 26.2 3.5 × 10.sup.6 74 sec.sup.-1 7.4 50.5 6.8 × 10.sup.5 74 70.2 9.4 × 10.sup.4D Ba 0.74 35.1 4.7 × 10.sup.6 30 sec.sup.-1 7.4 59.4 8.0 × 10.sup.5 74 -- --E Mg 0.74 6.0 8.1 × 10.sup.5 740 sec.sup.-1 7.4 10.9 1.5 × 10.sup.5 74 20.5 2.8 × 10.sup.4 740 40.2 5.4 × 10.sup.3F Ba 0.74 6.9 9.2 × 10.sup.5 149 sec.sup.-1 7.4 14.1 1.9 × 10.sup.5 74 25.1 3.4 × 10.sup.4 740 50.1 6.7 × 10.sup.3__________________________________________________________________________
EXAMPLE 5
A sample of sulfonated Vistalon 2504 was prepared according to the procedure of Examples 2 and 3. The acid form of the sulfonated EPDM polymer contained about 22.8 meq. SO 3 H groups per 100 grams of the polymer.
Samples of these materials were formulated according to the gum, black, and oil-black formulations as described in Example 4 except that 13 grams of magnesium stearate and barium stearate were used per 100 grams of polymer. The samples were compression molded at 325° F. for 45 minutes. All the compression molded pads were smooth and shiny. The tensile properties of the molded samples are given in Table IX and the rheological properties are summarized in Table X.
This example and Example 4 shows the rheological behavior of the neutralized sulfonated EPDM elastomeric polymers varies as a function of the sulfonate content, metal counterion and formulation.
TABLE IX__________________________________________________________________________ At Room Temperature At 100° C. 300% Tensile 300% TensileMetal Modulus, Strength, Elong., Modulus, Strength, Elong.,Stearate Formulation psi psi % psi psi %__________________________________________________________________________Magnesium Gum 520 4680 620 200 440 700Barium Gum 610 3135 550 180 270 570Magnesium Black 1820 3060 530 550 800 520Barium Black 1890 2861 490 630 845 450Magnesium Oil-Black 760 922 440 260 260 330Barium Oil-Black 780 924 375 240 270 380__________________________________________________________________________
TABLE X__________________________________________________________________________ Shear Stress Viscosity Shear RateMetal Formulation Shear Rate, Sec.sup.-1 Dynes/cm.sup.2 × 10.sup.-5 Poise At Fracture__________________________________________________________________________Mg Gum 0.74 15.1 2.0 × 10.sup.6 30 7.4 38.5 5.2 × 10.sup.5 74 63.9 8.6 × 10.sup.4Ba Gum 0.74 38.8 5.2 × 10.sup.6 0.3 7.4 56.9 7.7 × 10.sup.5 74 69.0 9.3 × 10.sup.4Mg Black 0.74 20.6 2.8 × 10.sup.6 30 7.4 47.7 6.4 × 10.sup.5 74 71.7 9.7 × 10.sup.4Ba Black 0.74 48.9 6.6 × 10.sup.6 7.4 7.4 72.6 9.8 × 10.sup.5 74 -- --Mg Oil-Black 0.74 6.3 8.5 × 10.sup.5 1500 7.4 11.8 1.6 × 10.sup.5 74 20.7 2.8 × 10.sup.4Ba Oil-Black 0.74 8.8 1.2 × 10.sup.6 74 7.4 15.0 2.0 × 10.sup.5 74 27.2 3.7 × 10.sup.4__________________________________________________________________________
EXAMPLE 6
A sample of sulfonated Vistalon 2504 was prepared according to the procedure of Examples 2 and 3. The acid form of the sulfonated EPDM polymer contained about 29.7 meq. SO 3 H groups per 100 grams of polymer.
Samples were prepared according to the following formula:
Sulfonated EPDM polymer: 100 grams
Metal Stearate: 16 grams
for the following metallic stearates: lithium, sodium, magnesium, zinc, lead, barium, and calcium. Compression molded pads were made for each sample at 325° F. for 15 minutes, wherein each sample was smooth and shiny. The tensile and volume swell properties for these samples are summarized in Table XI. The data show that outstanding gum physical properties can be obtained by bulk neutralization and that the rheological and physical properties are a function of the metal counterion.
TABLE XI______________________________________GUM FORMULATION.TESTED AT ROOM TEMPERATURE.Metal 300% Tensile Elongation, VolumeStearate Modulus, psi Strength, psi % Swell, %______________________________________Li 380 2120 590 340Na 590 4280 620 310Mg 550 3930 600 230Zn 410 3270 630 340Pb 580 3710 590 330Ba 700 3320 540 250Ca 550 4290 570 270______________________________________
EXAMPLE 7
A sample of sulfonated Vistalon 2504 was prepared according to the procedure of Examples 2 and 3. The acid form of the sulfonated EPDM terpolymer had about 15.3 meq. SO 3 H groups per 100 grams of polymer.
The acid form of the sulfonated EPDM polymer was mixed on a two roll rubber mill with the following metal stearates: magnesium, barium, calcium, sodium, lead, aluminum, iron, and zinc. The amount of each stearate used is illustrated in Table XII with the resultant tensile properties for a compression molded pad for each sample at 325° F. for 45 minutes. Each pad was smooth and shiny. The data show clearly that very good physical properties are obtainable for gums at low levels of sulfonate. The rheological properties are summarized in Table XIII which shows that flow can be made to vary with the metal counter-ion.
TABLE XII______________________________________ 300% TensileMetal Parts Per Modulus, Strength, Elongation,Stearate 100 of Polymer psi psi %______________________________________Mg 11 470 2260 630Ba 13.3 440 1570 550Ca 11.4 310 1450 605Na 11.5 390 1390 560Pb 14.6 290 1410 550Al 1.3 310 905 550Fe 1.3 -- 820 610Zn 12 320 970 540______________________________________
TABLE XIII______________________________________ Shear Stress, Dynes/cm.sup.2 × 10.sup.-5 MeltMetal Parts Per 0.74 147 740 FractureStearate 100 of Polymer sec.sup.-1 sec.sup.-1 sec.sup.-1 sec.sup.-1______________________________________Zn 12 3.19 39.0 63.5 ≦295Pb 14.6 6.62 49.9 77.1 295Fe 11.3 6.62 51.8 72.8 74Mg 11 13.47 66.6 89.6 29Al 11.3 14.80 65.8 91.9 14.7Na 11.5 16.52 67.4 91.9 74Ca 11.4 21.58 69.3 94.3 14.7Ba 13.3 24.70 74.0 95.8 14.7______________________________________
EXAMPLE 8
The sulfonated polymer of Example 6 was compounded on a cold two roll mill according to the following formulation:
______________________________________ Grams______________________________________Sulfonated EPDM polymer 100SRF Carbon Black 75FEF Carbon Black 75Flexon 845 Oil 100Metal Stearate 16______________________________________
wherein a sample was prepared from magnesium stearate and another sample was prepared from barium stearate. In each case, the metal stearate was added after a homogeneous mixture of the sulfonated polymer, carbon blacks, and oil had been achieved. The samples were compression molded into pads at 325° F. for 45 minutes and the resultant pads for the two samples were smooth and shiny. The tensile properties of the samples are summarized in Table XIV and the rheological properties are summarized in Table XV. These samples clearly illustrate that extended products can have excellent room temperature properties, as well as good 100° C. tensile properties while still possessing excellent rheological properties for extrusion or injection molding.
TABLE XIV__________________________________________________________________________Room Temperature 100° C.300% Tensile 300% TensileMetalModulus, Strength, Elongation, Modulus, Strength, Elongation,Stearatepsi psi % psi psi %__________________________________________________________________________Mg 855 1100 420 365 360 340Ba 820 1080 440 320 350 360__________________________________________________________________________
TABLE XV______________________________________ ShearMetal Shear Shear Stress Viscosity, Rate AtStearate Rate, sec.sup.-1 Dynes/cm.sup.2 × 10.sup.-5 Poise Fracture______________________________________Mg 0.74 6.3 8.5 × 10.sup.5 1500 7.4 12.2 1.6 × 10.sup.5 sec.sup.-1 74 21.1 2.8 × 10.sup.4 740 41.0 5.5 × 10.sup.3Ba 0.74 9.9 1.3 × 10.sup.6 150 7.4 17.1 7.0 × 10.sup.5 sec.sup.-1 74 29.2 3.9 × 10.sup.4 740 68.2 9.2 × 10.sup.3______________________________________
EXAMPLE 9
Neat acetyl sulfate was prepared as follows: 164.8 grams (1.61 moles) of acetic anhydride was cooled to -30° C. and 97.9 grams (1.0 mole) of concentrated sulfuric acid was added slowly so that the temperature did not exceed 0° C. After all the sulfuric acid was added, the thick mixture was warmed at 10° C. and then used for sulfonation. The neat acetyl sulfate is 4.84 Molar.
Five hundred grams of Vistalon 2504 was dissolved in 10 liters of heptane and 52 ml of the 4.84 Molar acetyl sulfate was added at room temperature. After 60 minutes of stirring, the reaction was terminated with 200 ml of stabilized methanol. The acid form of the sulfonated EPDM was recovered by steam stripping, and the elastomeric mass was pulverized in a Waring blender with stabilized methanol. The sulfonated polymer was dewatered on a rubber mill at 104° F., and when the mass had fused and banded, it was kept on the mill for two more minutes. Titration of the sulfonated polymer showed it contained about 37.4 meq. SO 3 H groups per 100 grams of polymer. A second sample prepared had about 39.4 meq. SO 3 H groups per 100 grams of polymer. A blend of the two preparations, used in the following formulas, had 36.4 meq. SO 3 H groups per 100 grams of polymer.
The following formulations were prepared on a two roll mill from the acid form of the sulfonated EPDM polymer.
______________________________________(A) Polymer 100 parts Metal Stearate 2 equivalents/mole SO.sub.3 H(B) Polymer 100 parts Metal Stearate 3 equivalents/mole SO.sub.3 H(C) Polymer 100 parts SRF Black 75 parts FEF Black 75 parts Flexon 845 Oil 100 parts Metal Stearate 2 equivalents/mole SO.sub.3 H(D) Polymer 100 parts SRF Black 75 parts FEF Black 75 parts Flexon 845 Oil 100 parts Metal Stearate 3 equivalents/mole SO.sub.3 H______________________________________
Each of the formulations were made with the sodium and magnesium salts of octanoic, decanoic, lauric, myristic, palmitic, and stearic acids. In the oil-black formulations, the oil and carbon black were well dispersed prior to the addition of the metal carboxylate.
Test plaques were compression molded at 325° F. for 45 minutes, and all the plaques were smooth and shiny. Table XVI shows the tensile properties of these samples at room temperature while Table XVII shows their tensile properties at 100° F. The data clearly shows that a plurality of metal salts of carboxylic acids can be used in bulk neutralization. Table XVIII summarizes the rheological properties of the oil-black samples, wherein these formulations possess very low viscosities at low shear rates which is desirable for an extrusion process or a high speed injection molding operation.
TABLE XVI__________________________________________________________________________ROOM TEMPERATURE PHYSICAL PROPERTIES(TENSILE STRENGTH, PSI/ELONGATION, %)OF SULFO-EPDM BULK NEUTRALIZED WITH THE SODIUM AND MAGNESIUM SALTSOF VARIOUS FATTY ACIDSOIL-BLACK Sodium Salts Stearate Palmitate Myristate Laurate Decanoate Octanoate__________________________________________________________________________ 2 Equivalents 1010/330 1050/340 930/305 880/345 800/325 730/350 3 Equivalents 990/310 1050/300 840/210 930/250 775/280 830/240 Magnesium Salts 2 Equivalents 1010/320 1070/390 805/310 870/395 880/360 -- 3 Equivalents 1060/430 1035/430 890/450 870/420 840/430 --GUM Sodium Salts 2 Equivalents 4330/555 4150/525 3555/510 2500/475 1740/450 1940/460 3 Equivalents 3870/550 3820/560 1880/470 535/190 2280/480 2170/480 Magnesium Salts 2 Equivalents 4090/570 3920/590 2250/510 2740/525 2090/490 -- 3 Equivalents 4660/630 3850/630 4050/570 3165/530 3030/525 --__________________________________________________________________________
TABLE XVII__________________________________________________________________________100° C. PHYSICAL PROPERTIES (TENSILE STRENGTH, PSI/ELONGATION, %)OF SULFO-EPDM BULK NEUTRALIZED WITHTHE SODIUM AND MAGNESIUM SALTS OF VARIOUS FATTY ACIDSOIL-BLACK Sodium Salts Stearate Palmitate Myristate Laurate Decanoate Octanoate__________________________________________________________________________ 2 Equivalents 50/280 80/250 90/250 280/200 280/200 200/180 3 Equivalents 110/210 180/160 170/160 420/190 250/120 240/150 Magnesium Salts 2 Equivalents 170/300 430/250 250/250 390/230 480/165 -- 3 Equivalents 270/350 560/290 300/320 330/320 400/215 --GUM Sodium Salts 2 Equivalents 420/750 540/660 480/490 770/400 410/390 320/420 3 Equivalents 630/720 730/630 340/460 410/140 400/400 410/400 Magnesium Salts 2 Equivalents 220/610 590/510 500/450 330/520 425/335 -- 3 Equivalents 970/730 840/490 820/610 520/525 430/420 --__________________________________________________________________________
TABLE XVIII__________________________________________________________________________Carboxylic Equivalents/ Shear Stress,Dynes/cm.sup.2 × 10.sup.-5 Melt Fracture,Metal Acid SO.sub.3 H 0.74 sec.sup.-1 7.4 sec.sup.-1 74 sec.sup.-1 740 sec.sup.-1 sec.sup.-1__________________________________________________________________________Na Stearic 2 2.6 6.3 12 25 2940Na Palmitic 2 2.4 -- 12 26 2940Na Myristic 2 2.4 -- 12 25 2940Na Lauric 2 3.2 -- 13 31 2940Na Decanoic 2 2.6 -- 11 23 >2940Na Octanoic 2 2.5 -- 11 22 >2940Na Stearic 3 1.6 -- 9.4 Pulsates >2940Na Palmitic 3 1.6 -- 9.6 Pulsates >2940Na Myristic 3 1.6 -- 9.2 Pulsates >2940Na Lauric 3 2.1 -- 10.6 Pulsates >2940Na Decanoic 3 1.6 -- 9.1 17.6 740Na Octanoic 3 1.7 -- 9.1 Pulsates >2940Mg Stearic 2 2.4 -- 11 24 2940Mg Palmitic 2 3.3 -- 12 33 2940Mg Myristic 2 2.8 -- 11 26 2940Mg Lauric 2 2.7 -- 11 24 2940Mg Decanoic 2 2.8 -- 11 24 2940Mg Stearic 3 1.9 -- 9.8 Pulsates >2940Mg Palmitic 3 1.9 -- 9.1 Pulsates >2940Mg Myristic 3 1.9 -- 9.2 Pulsates >2940Mg Lauric 3 2.0 -- 10.0 Pulsates >2940Mg Decanoic 3 2.2 -- 10.5 Pulsates >2940__________________________________________________________________________
EXAMPLE 10
Two hundred grams of a higher molecular weight EPDM elastomer (Vistalon 3708) having a Mooney viscosity (ML, 1+8, 260° F.) of about 45-55, an Mn of about 52,300, and an Mv of about 270,000, was dissolved in 5000 ml of hot chlorobenzene, and the temperature was maintained at 50° C. To the resultant cement was added 50 ml of 0.996 M acetyl sulfate in chlorobenzene and the reaction was maintained at 50° C. for 30 minutes. The reaction was quenched with 100 ml of stabilized methanol. The sulfonated EPDM was steam stripped, washed twice with methanol in a Waring blender, and dewatered at 110° F. on a two roll rubber mill until the crumb formed a lace. The lace was washed twice again with stabilized methanol, dewatered again, dried and stabilized with 1.0 grams of Antioxidant 2246 on the two roll mill at 110° F. The resultant acid form of the sulfonated EPDM elastomeric polymer had 21.3 meq. SO 3 H groups per 100 grams of polymer.
The following formulations were mixed on a cold two roll rubber mill, wherein the magnesium stearate was added after a homogeneous mixture of the acid form of the sulfonated EPDM, oil and black had been achieved.
______________________________________(1) Sulfonated EPDM 100 grams Magnesium Stearate 16 grams(2) Sulfonated EPDM 100 grams FEF Black 50 grams Magnesium Stearate 16 grams(3) Sulfonated EPDM 100 grams FEF Black 75 grams SRF Black 75 grams Flexon 845 Oil 100 grams Magnesium Stearate 16 grams______________________________________
Test samples were prepared by compression molding at 325° F. for 45 minutes. The tensile properties of these samples are summarized in Table XIX and the rheological properties are shown in Table XX. The neutralized magnesium gums possess an exceptionally high viscosity. Mixing of such high viscosity gums with extender oils and fillers is extremely difficult and dispersion is poor due to the limited wetability of the filler by the polymeric matrix during mixing. Therefore, it is possible to produce a final formulation of superior physical and rheological properties which would have been impossible, if the oil and filler had been mixed directly into the neutralized sulfonated EPDM instead of premixing the fillers and oils into the acid form of the sulfonated EPDM and then neutralizing. The neutralized gums are so intractible that mixing fillers and extenders therein is not possible or practical.
TABLE XIX__________________________________________________________________________Polymer Example 10 Example 11Formulation 1 2 3 1 2 3__________________________________________________________________________Room Temperature300% Modulus, psi 750 1940 840 -- -- --Tensile Strength, psi 3785 2840 1050 -- -- --Elongation, % 570 430 430 -- -- --Tensile Set, % 56 50 31 -- -- --100° C.300% Modulus, psi -- -- -- -- -- --Tensile Strength, psi 200 580 200 430 910 450Elongation, % 420 300 270 150 190 280Tensile Set, % 42 12.4 18.6 6.2 6.2 12.4__________________________________________________________________________
TABLE XX______________________________________ Formu- Shear Rate Shear Stress Viscosity,Example lation sec.sup.-1 Dynes/cm.sup.2 × 10.sup.5 Poise______________________________________10 1 0.74 32.3 4.4 × 10.sup.6 7.4 54.9 7.5 × 10.sup.5 74 69.7 9.5 × 10.sup.410 3 0.74 9.0 1.2 × 10.sup.6 7.4 15.3 2.1 × 10.sup.5 74 24.5 3.3 × 10.sup.4 740 43.2 5.9 × 10.sup.311 1 0.74 47.1 6.4 × 10.sup.6 7.4 66.6 9.0 × 10.sup.5 74 76.0 1.0 × 10.sup.511 3 0.74 14.5 2.0 × 10.sup.6 7.4 21.0 2.9 × 10.sup.5 74 30.9 4.2 × 10.sup.4 740 54.9 7.5 × 10.sup.3______________________________________
EXAMPLE 11
A sulfonated EPDM of Vistalon V-3708 was made according to the procedure of Example 10, wherein the resultant acid form of the sulfonated EPDM had 29.2 meq. SO 3 H groups per 100 grams of polymer. This polymer was mixed according to the formulations of Example 10 and test samples were prepared by compression molding at 325° F. for 45 minutes. The tensile data are again given in Table XIX, and the rheological properties are summarized in Table XX. The increased sulfonation of the EPDM should decrease the rheological properties; however, superior materials can be still produced by first mixing the fillers and extender oils into the polymeric acid and then bulk neutralizing the homogeneous mixture with metal salt of a carboxylic acid.
EXAMPLE 12
Two hundred grams of Vistalon 2504 was dissolved in 4000 ml of hexane. To the resultant cement was added 11.47 ml. of acetic anhydride, and then 4.2 ml of concentrated sulfuric acid was dripped in at room temperature. The reaction was stirred for thirty minutes at room temperature and the sulfonation was quenched with 100 ml of stabilized methanol. The acid form of the sulfonated EPDM was isolated by steam stripping, washed with water in a Waring blender, dewatered, and dried on a two roll mill at 110° F. The following formulations were made from the acid form of the sulfonated EPDM, wherein the metal salt of the carboxylic acid was added after a homogeneous mixture of the acid form, filler and oil had been achieved.
______________________________________(1) Sulfonated EPDM 100 grams Magnesium Stearate 23.5 grams(2) Sulfonated EPDM 100 grams Magnesium Acetate . 4H.sub.2 O 8.5 grams(3) Sulfonated EPDM 100 grams FEF Black 75 grams SRF Black 75 grams Flexon 845 Oil 100 grams Magnesium Stearate 23 grams(4) Sulfonated EPDM 100 grams FEF Black 75 grams SRF Black 75 grams Flexon 845 Oil 100 grams Magnesium Acetate . 4H.sub.2 O 8.5 grams______________________________________
These formulations were compression molded at 325° F. for 15 minutes. The physical properties are summarized in Table XXI and the rheological properties are shown in Table XXII. A fifth formulation was prepared according to the recipe of formulation 4, wherein the acid form was first neutralized with the magnesium acetate and then the filler and oil were added. The physical and rheological properties of formulation five are also summarized in Tables XXI and XXII. The formulations with magnesium stearate exhibited improved rheological properties as compared to those of magnesium acetate. In attempting to remold the test pads of formulation 2, it was not possible to make good, well-knitted pads. The rheological properties of formulation 5 are inferior to formulation 4. Thus, better rheological properties are achieved by first forming a homogeneous mixture of the acid form, filler, and oil and then bulk neutralizing with the metal salt of the carboxylic acid.
TABLE XXI______________________________________Formulation 1 2 3 4 5______________________________________Room TemperatureTensile Strength, psi 3130 580 820 730 650Elongation, % 600 270 370 290 260100° C.Tensile Strength, psi 240 240 190 240 --Elongation, % 490 80 290 80 --______________________________________
TABLE XXII______________________________________ Shear Shear RateFormu- Rate, Shear Stress, Viscosity, at Fracturelation sec.sup.-1 Dynes/cm.sup.2 × 10.sup.5 Poise sec.sup.-1______________________________________1 0.88 16.4 -- 29 8.8 38.9 -- 88 65.5 -- 294 80.4 --2 0.88 38.9 -- 0.9 8.8 56.6 -- 88 71.8 -- 294 84.3 --3 0.88 4.1 -- 1469 8.8 9.2 -- 88 17.2 -- 294 26.2 --4 0.88 7.5 -- 88 8.8 13.6 -- 88 26.1 -- 294 38.0 --5 0.88 13.4 -- 9 8.8 24.0 -- 88 41.0 -- 294 57.7 --______________________________________
EXAMPLE 12
A Vistalon 2504 was sulfonated according to the procedures of Examples 2 and 3 and worked up as previously described. The acid form of the sulfonated EPDM had 28.8 meq. SO 3 H groups per 100 grams of polymer.
The following formulation was prepared on a two roll mill, wherein the magnesium oxide was added after a homogeneous mixture of acid form, the blacks and oil had been achieved.
Sulfonated EPDM: 100 grams
FEF Black: 75 grams
SRF Black: 75 grams
Flexon 845 Oil: 100 grams
MgO: 2.5 grams
Test specimens were compression molded at 325° F. for 45 minutes. The physical properties are given in Table XXIII and the rheological properties are summarized in Table XXIV. The final molded products had excellent physical properties, but considerably poorer rheological properties than obtainable with bulk neutralization with magnesium stearate. Metallic oxides can be used to bulk neutralize the acid form of the sulfonated elastomeric polymer thereby resulting in a product with excellent physical properties.
EXAMPLE 13
The acid form of the sulfonated EPDM of Example 12 was compounded on a cold two roll rubber mill according to the following formulations wherein the magnesium stearate and the magnesium oxide were added last.
______________________________________(1) Sulfonated EPDM 100 grams Silene D-250 (Silica Filler) 250 grams Flexon 580 125 grams Magnesium Stearate 16 grams2 Sulfonated EPDM 100 grams Silene D 250 grams Flexon 580 125 grams MgO 10 grams______________________________________
Compression molded plaques were prepared at 325° F. for 45 minutes. The physical properties are summarized in Table XXIII and the rheological properties are given in Table XXIV. Samples could not have been prepared unless the filler and oil was first mixed with the acid form of the sulfonated EPDM and then bulk neutralized with the magnesium oxide or magnesium stearate.
TABLE XXIII______________________________________Example 12 13 13______________________________________Formulation 1 2Room Temperature300% Modulus, psi -- -- --Tensile Strength, psi 1210 765 960Elongation, % 290 230 200Tensile Set, % 21 -- --100° C.300% Modulus, psi -- -- --Tensile Strength, psi 570 400 530Elongation, % 130 200 112Tensile Set, % -- -- --______________________________________
TABLE XXIV______________________________________ Shear Rate, Shear Stress, Viscosity,Example Formulation sec.sup.-1 Dynes/cm.sup.2 × 10.sup.5 Poise______________________________________12 0.74 12.4 1.68 × 10.sup.6 7.4 20.1 2.7 × 10.sup.5 74 36.3 4.88 × 10.sup.4 740 -- --13 1 0.30 8.2 2.8 × 10.sup.5 0.74 -- -- 7.4 -- -- 14.9 19.1 1.3 × 10.sup.5 74 31.5 4.2 × 10.sup.4 740 78.1 1.1 × 10.sup.413 2 0.30 19.7 6.6 × 10.sup.6 0.74 22.6 3.0 × 10.sup.6 7.4 35.1 4.7 × 10.sup.5 14.9 38.6 2.6 × 10.sup.5 74 52.0 7.0 × 10.sup.4 740 -- --______________________________________
EXAMPLE 14
A commercial EPDM, Vistalon 6505, was reduced in molecular weight through a controlled extrusion process. The final Mooney viscosity (ML, 1+8, 212° F.) was about 20. Five hundred grams of this polymer was dissolved in 5000 ml of hexane. To the cement was added 405 mmoles of acetic anhydride followed by 250 mmoles of concentrated sulfuric acid. After stirring for 30 minutes at room temperature sulfonation was terminated through the addition of 750 ml methanol. Antioxidant 2246 (2.5 g) was added to the terminated cement, and the sulfonated polymer was isolated through steam stripping, washing with water in a Waring blender, and then dewatering the wet crumb on a rubber mill at about 110° F. The polymeric free acid contained 20.3 meq. free sulfonic acid/100 polymer according to sulfur analysis. The polymeric sulfonic acid was mixed according to the formulations in Table XXV. In every case the neutralizing agent was added last. Tensile test pads and samples for melt index measurement were molded 15 minutes at 350° F.
The room temperature tensile properties and the melt index at 190° C. and 250 psi are given in Table XXV.
This example demonstrates the use of a high unsaturation EPDM, three different carbon blacks, three different oils, three different metal stearates, at filler loadings of up to 200 parts, and at oil loadings of up to 75 parts.
TABLE XXV______________________________________Sulfonated V-6505 100 100 100 100Thermex (MT Black) 200 -- -- --P-33 (FT Black) -- -- 150 --Spheron 9 (EPC Black) -- -- -- 100Sunpar 2280 -- 50 -- --Sundex 790 -- -- 50 --Sunthene 4240 -- -- -- 75Zinc Stearate 28.5 19 -- --Lead Stearate -- -- 35 --Barium Stearate -- -- -- 31.7Tensile Strength, psi 560 50 300 220Elongation, % 70 420 380 290Melt Index (190° C., 250 psi), 5.9 1.6* >50 0.8g/10 minutes______________________________________ *At 6.5 psi
EXAMPLE 15
Five hundred grams of Butyl 365, which contains about 2.0 mole % unsaturation and has a Mooney viscosity (ML, 1+8, 212° F.) of about 45, was dissolved in 5000 ml of hexane. To the cement was added 304 mmoles of acetic anhydride followed by 187.5 mmoles of concentrated sulfuric acid. After 30 minutes agitation at room temperature sulfonation was terminated with 200 ml methanol. Antioxidant 2246 (2.5 g) was added and the sulfonated polymer was isolated and dewatered as described in Example 14. The polymeric sulfonic acid contained 30.9 meq. of free sulfonic acid/100 polymer according to sulfur analysis. Mixtures of this polymeric sulfonic acid were made according to the formulations in Table XXVI. In every case the neutralizing agent was added last. Tensile test pads and samples for melt index were molded 15 minutes at 350° F. The room temperature tensile properties and the melt index at 190° F. and 250 psi are given in Table XXVI.
This example demonstrates the use of a Butyl rubber, three different carbon blacks, three mineral fillers, three different oils, four different metal stearates, and zinc oxide neutralizing agent.
TABLE XXVI__________________________________________________________________________Sulfonated Butyl 365 100 100 100 100 100 100 100Spheron 9 (EPC Black) 50 -- -- -- -- -- --Philblack A (FEF Black) -- 50 -- -- -- -- --Philblack E (SAF Black) -- -- 50 -- -- -- --Purecal U -- -- -- -- 100 -- --Icecap K -- -- -- -- -- 100 --Silene D -- -- -- -- -- -- 100Sunpar 2280 -- -- -- -- 50 -- --Sundex 790 -- -- -- -- -- 50 50Sunthene 4240 27.6 -- -- -- -- -- --Sodium Stearate -- 27.3 -- -- -- -- --Calcium Stearate -- -- 26.6 -- -- 26.6 --Magnesium Stearate -- -- -- 50 28.5 -- --Zinc Stearate -- -- -- -- -- -- 6Zinc Oxide -- -- -- -- -- -- --Tensile Strength, psi. 1420 1410 1705 1930 890 590 820Elongation, % 710 670 520 >1000 810 800 393Melt Index (190° C., 250 psi),g/10 minutes 10.7 1.9 0.1 0.2* 0.1* 10.9 0__________________________________________________________________________ *At 6.5 psi.
EXAMPLE 16
Commercial Vistalon 2504 was reduced in molecular weight through a controlled extrusion process. The final Mooney viscosity (ML, 1+8, 212° F.) was about 20. Five hundred grams of this polymer was dissolved in 5000 ml of hexane, and sulfonation and polymer isolation was conducted as described in Example 15. The polymeric sulfonic acid contained 32.8 meq. of free sulfonic acid per 100 of polymer according to sulfur analysis. The polymeric sulfonic acid was mixed according to the formulations in Table XXVII. In every case the neutralizing agent was added last. Tensile test pads and samples for melt index were molded 15 minutes at 350° F. The room temperature tensile properties and the melt index at 190° C. and 250 psi are given in Table XXVII.
This example demonstrates that lower melt viscosities are achievable through the use of a lower Mooney EPDM. Also demonstrated are the use of two carbon blacks, three mineral fillers, three oils, three metal stearates and four metal oxide neutralizing agents, wherein up to 50 parts of a metal stearate neutralizing agent was used.
TABLE XXVII__________________________________________________________________________Sulfonated V-2504 100 100 100 100 100 100 100 100 100Thermex (MT Black) 150 -- -- -- -- -- -- -- --Philblack E (SAF Black) -- -- -- -- -- -- 150 -- --Atomite -- 100 -- -- -- -- -- -- --Mistron Vapor -- -- 100 -- -- -- -- -- --HiSil 215 -- -- -- 100 -- 100 -- -- --Sunthene 4240 100 -- -- -- -- -- 100 100 100Sundex 790 -- 50 -- 50 -- -- -- -- --Sunpar 2280 -- -- 50 -- -- 50 -- -- --Zinc Stearate 28.5 -- -- 50 50 -- -- -- --Magnesium Stearate -- 26.6 -- -- -- -- -- -- --Lead Stearate -- -- 35 -- -- -- -- -- --Zinc Oxide -- -- -- -- -- 5 -- -- --PbO.sub.2 -- -- -- -- -- -- 5 -- --Pb.sub.3 O.sub.4 -- -- -- -- -- -- -- 5 --Magnesium Oxide -- -- -- -- -- -- -- -- 5Tensile Strength, psi. 260 1050 1140 780 2960 620 950 880 1120Elongation, % 330 720 320 430 615 90 270 260 350Melt Index (190° C., 250 psi),g/10 minutes 0.4* 2.2 15.4 5.3 10.4 0 0.15 0.5 0__________________________________________________________________________ *At 6.5 psi
EXAMPLE 17
One hundred grams of Butyl HT 1066, a chlorinated Butyl rubber, was dissolved in 1000 ml of hexane. To the cement was added 60.8 mmoles acetic anhydride followed by 37.5 mmoles of concentrated sulfuric acid. After 30 minutes stirring at room temperature the sulfonation was terminated through the addition of 100 ml of methanol. Antioxidant 2246 (0.5 g) was added, and the cement was isolated and dewatered as described in Example 15. The polymeric sulfonic acid contained 10 meq. of sulfonic acid/100 polymer and was mixed according to the formulations in Table XXVIII. In every case the neutralizing agent was added last. Tensile test pads and samples for melt index were molded 15 minutes at 350° F. The room temperature tensile properties and the melt index at 190° C. and 250 psi are given in Table XXVIII.
This example demonstrates the use of chlorinated Butyl rubber containing as little as 10 meq. of sulfonic acid per 100 of polymer.
TABLE XXVIII______________________________________Sulfonated Butyl HT 1066 100 100 100 100Philblack E (SAF Black) -- -- 75 --Philblack O (HAT Black) -- -- 75 --Dixie Clay -- -- -- 100Sunpar 2280 -- -- 100 --Zinc Stearate 28.5 50 -- 28.5Lithium Stearate -- -- 26.1 --Tensile Strength, psi 480 360 60 175Elongation, % 800 750 130 800Melt Index (190° C., 250 psi),g/10 minutes 0.3 7.7 0 0.03*______________________________________ *At 6.5 psi
EXAMPLE 18
A commercial terpolymer, Nordel 1320, a terpolymer of ethylene, propylene and 1,5-hexadiene, was used in this example. Five sulfonations were made. Neat acetyl sulfate was prepared as described in Example 9. Sulfonations were effected at 50° C. for a period of 60 minutes in heptane solvent at a Nordel 1320 concentration of 70 g/liter heptane. Sulfonations were terminated with 5 volume % isopropanol containing Antioxidant 2246. The sulfonated polymers were isolated and dewatered as described in earlier examples.
Sulfonate contents were determined by both sulfur analysis and titration. In the titration 5.0 g of sulfonated polymer was dissolved in 95 ml toluene and 5 ml methanol, and the solution was titrated with 0.1 N ethanolic NaOH to an alizarin-thymolphthalein end-point. The results of the sulfonations are given in Table XXIX.
The results of the analyses show that the Type II unsaturation (symmetrically disubstituted olefin) contained in Nordel 1320 is more difficult to sulfonate than the Type IV unsaturation derived from 5-ethylidene-2-norbornene in the Vistalon EPDM's.
These five polymeric sulfonic acids were mixed on a rubber mill with 3 equivalents of magnesium stearate per equivalent of sulfonic acid in a gum and oil black formulation.
______________________________________Gum Oil Black______________________________________Polymer 100 Polymer 100Magnesium Stearate Var. Pelletex NS (SRF Black) 75 Philblack A (FEF Black) 75 Flexon 845 100 Magnesium Stearate Var.______________________________________
The mixed formulations were molded for 10 minutes at 350° F. into micropads for testing and 8 minutes at 350° F. into 70 mil 2-inch×6-inch plaques for rheological studies. Tensile data are given in Table XXX, and rheological properties are shown in Table XXXI.
TABLE XXIX__________________________________________________________________________SULFONATION OF NORDEL 1320 From Titration From Sulfur AnalysisExampleAcetyl Sulfate SO.sub.3 H Content, SO.sub.3 H Content, ReagentNumberMmole/100 g. Nordel Meq/100 g Meq/100 g Conversion, %__________________________________________________________________________18-A 40.0 21.8 16.9 4218-B 50.0 25.4 21.3 4318-C 60.0 25.6 22.2 3718-D 70.0 20.9 25.0 3618-E 80.0 32.6 31.3 39__________________________________________________________________________
TABLE XXX______________________________________TENSILE PROPERTIES OF BULK NEUTRALIZEDSULFONATED NORDEL 1320Room Temperature 100° C. Tensile 300% Elong- Tensile 300% Elong-Ex- Strength, Modulus, ation, Strength, Modulus, ation,ample psi psi % psi psi %______________________________________Gum Formulation18-D 3650 590 705 -- -- --18-E 4120 620 710 -- -- --Oil Black Formulations18-A 560 390 690 90 -- 41018-B 670 440 750 170 140 45018-C 830 540 780 180 150 47018-D 730 455 700 190 170 42018-E 860 500 660 205 170 440______________________________________
TABLE XXXI______________________________________RHEOLOGY SUMMARY OF BULK NEUTRALIZEDSULFONATED NORDEL 1320At 0.74 sec.sup.-1 Shear Stress, Viscosity Shear Rate AtExample Dynes/cm.sup.2 × 10.sup.-5 Poise × 10.sup.-5 Fracture, sec.sup.-1______________________________________Gum Formulations18-A 11.2 15.1 73518-B 10.1 13.6 73518-C 13.1 17.7 29518-D 11.5 15.5 75318-E 10.4 14.1 735Oil Black Formulations18-A 2.0 2.7 >294018-B 2.1 2.8 >294018-C 2.4 3.2 >294018-D 4.1 5.5 147018-E 3.2 4.3 1470______________________________________
The improved elastomeric blend compositions prepared by the process of this invention can be fabricated into a plurality of useful articles. For example, wire, film, washer hose and radiator hose can be made by an extrusion process from these compositions. The compositions can be used for shoe heels. Sight shields, screw driver handles, spark plug covers and automobile bumper assemblies can all be made by injection molding process.
Since many modifications and variations of this invention may be made without departing from the spirit or scope of the invention thereof, it is not intended to limit the spirit or scope thereof to the specific examples thereof.
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An improved process for the manufacture of extended gel free sulfonated elastomeric products includes the formation of a homogeneous mixture of fillers and oils with the acid form of the sulfonated polymer prior to the neutralization of the acid form of the sulfonated polymer with a basic material thereby resulting in a composition having improved physical properties.
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The present disclosure relates to the subject matter disclosed in German patent application No. 10 2007 015 154.5 of Mar. 22, 2007, which is incorporated herein by reference in its entirety and for all purposes.
BACKGROUND OF THE INVENTION
The present invention relates to a holding device for an implant, comprising a first connecting device for releasably connecting the holding device and the implant.
The present invention also relates to a storage unit for accommodating and/or securing at least one holding device for an implant in place, wherein the holding device comprises a first connecting device for releasably connecting the holding device and the implant.
A holding device of the type described at the outset is known, for example, from U.S. Pat. No. 6,929,646 B2. This holding device has an elongated handle portion, with the aid of which an implant connected to the handle portion can be brought into a desired implanting position and location relative to a body part to be operated. After the implant has been attached to the body part, the handle portion can be separated from the implant.
It has been shown that the organization and handling of, in particular, very small implants is a problem. These implants differ from one another, at times, only very slightly but must be made available in numerous variations for a specific operation so that a surgeon can decide during the course of an operation which of the implants altogether available should be used. In some countries it is, in addition, necessary to document exactly what and how many implants have been used during the course of an operation.
It would, therefore, be desirable to make a holding device and a storage unit of the type described at the outset available, with which very small implants, in particular, are easy to handle.
SUMMARY OF THE INVENTION
In the case of a holding device of the type described at the outset, it is suggested that the holding device have a second connecting device for releasably connecting the holding device and a storage unit. The holding device therefore makes it possible, with the aid of a first connecting device, to secure an implant or several implants releasably in place on the holding device. With the aid of the second connecting device of the holding device, this can be releasably connected to a storage unit. The holding device of a further development enables a separate holding device to be made available for each implant or for a group of implants so that each implant or each group of implants can be handled more easily with the aid of the associated holding device. The holding devices may be connected to the storage unit such that the implants can be clearly arranged and can be handled together with the aid of the storage unit.
The first connecting device and the second connecting device can preferably be actuated independently of one another. As a result, an implant can be connected to the holding device with the aid of the first connecting device and be released from the holding device in that the first connecting device is actuated. This actuation is independent of whether the holding device is connected to the storage unit with the aid of the second connecting device or is released from it. In a corresponding manner, the second connecting device can be actuated in order to connect the holding device to the storage unit or release the holding device from the storage unit without this having any influence on the first connecting device and, therefore, on the connection between an implant and the holding device.
The first connecting device can preferably be transferred from a first connecting position, in which an implant can be or is connected to the holding device, into a first release position, in which the holding device releases the implant. As a result, the implant can be fixed reliably on the holding device in the first connecting position of the first connecting device and be removed from the holding device in a simple manner in the first release position of the first connecting device.
The first connecting device is preferably designed in such a manner that a first releasing force is required to transfer the first connecting device from the first connecting position into the first release position. The first releasing force defines the resistance which must be overcome for separation of the implant from the holding device. It is recommended that a releasing force be provided which is so great that an implant cannot be unintentionally detached from the holding device, for example, when the holding device is subject to slight shaking during transport. On the other hand, the first releasing force should be small enough for an implant to be releasable from the holding device manually or with the aid of a removing tool.
The holding device preferably comprises a first restoring device which transfers the first connecting device from the first release position into the first connecting position. A preferential position of the first connecting device can be defined with the aid of the first restoring device and this corresponds to the first connecting position. This preferential position can be taken up independently of whether an implant is held in the holding device or not.
It is favorable when the second connecting device can be transferred from a second connecting position, in which the holding device can be or is connected to the storage unit, into a second release position, in which the holding device can be released from the storage unit. In this way, the holding device can be secured reliably on the storage unit in the second connecting position of the second connecting device and so the holding device itself does not have to be handled but rather it can be handled with the aid of the storage unit. The holding device can be released from the storage unit in the second release position of the second connecting device so that the holding device can be handled independently of the storage unit.
The second connecting device is preferably designed in such a manner that a second releasing force is necessary to transfer the second connecting device from the second connecting position into the second release position. This second releasing force should be great enough to avoid any unintentional release of the holding device from the storage unit. The second releasing force should, on the other hand, be small enough to be able to remove the holding device from the storage unit preferably without the aid of tools.
In addition, it is preferred when the holding device comprises a second restoring device which transfers the second connecting device from the second release position into the second connecting position. A preferential position of the second connecting device can be defined with the aid of the second restoring device and this corresponds to the second connecting position. In this respect, a transfer into this preferential position can be carried out independently of whether the holding device is connected to the storage unit or not.
It is particularly preferred when the first releasing force and the second releasing force differ from one another according to amount and/or direction. As a result, any unintentional, simultaneous actuation of the first connecting device and the second connecting device can be avoided. It is, therefore, ensured that when the first releasing force is applied only the first connecting device is brought from the first connecting position into the first release position without this having any influence on the state of the second connecting device. In a corresponding manner, when the second releasing force is applied this causes a transfer of the second connecting device from the second connecting position into the second release position without this influencing the state of the first connecting device.
It is particularly preferred when the first releasing force and the second releasing force are linearly independent of one another. This makes it possible to decide, by selecting the corresponding release direction, whether the first connecting device is intended to be brought from the first connecting position into the first release position or whether the second connecting device is intended to be brought from the second connecting position into the second release position. As a result of the first and second release directions being linearly independent, it is possible to rule out that either of the two connecting devices will be brought from its connecting position into its release position in an unintentional manner. This applies irrespective of whether the first releasing force is smaller, the same as or greater than the second releasing force.
In addition, it is preferred when the first releasing force is smaller than the second releasing force. This makes it possible to adjust the releasing forces such that even when the releasing forces are intended to be oriented in the same direction the first connecting device will be brought, first of all, from the first connecting position into the first release position and then the second connecting device will be brought from the second connecting position into the second release position.
The first connecting device is preferably designed in such a manner that the implant can be handled in a first handling direction during movement from a first holding position, in which the implant is connected to the holding device, into a first release position, in which the implant is released from the holding device. With the handling direction it is possible to determine the direction, in which a surgeon must handle the implant in order to separate it from the holding device.
Furthermore, the second connecting device is preferably designed in such a manner that the holding device can be handled in a second handling direction during movement from a second holding position, in which the holding device is connected to the storage unit, into a second release position, in which the holding device is released from the storage unit. With the aid of the second handling direction it is possible to define the direction, in which the holding device must be handled in order to separate it from the storage unit.
It is particularly preferred when the first handling direction and the second handling direction are linearly independent of one another. When a surgeon releases an implant from the holding device in accordance with the first handling direction, any release of the holding device at the same time from the storage unit is precluded as a result of the linear independence of the handling directions. It is ensured in a corresponding manner that when the second handling direction is chosen to release the holding device from the storage unit an implant possibly connected to the holding device will not be released from the holding device.
It is particularly preferred when the first handling direction and the second handling direction are at right angles or essentially at right angles to one another. This makes a particularly simple handling of the implant, the holding device and the storage unit possible, with which any unintentional release of the implant from the holding device and any unintentional release of the holding device from the storage unit is precluded.
The holding device preferably defines a holding axis which predetermines the position and/or the location of the implant when it is connected to the holding device. In this way, it is possible to define an absolute spatial position and/or spatial location of an implant when the holding device is connected to a storage unit.
It is particularly preferred when the holding axis and the first handling direction are at right angles or essentially at right angles to one another. This makes a particularly simple and gentle transfer of the implant from the first holding position into the first release position possible.
It is favorable when the holding axis and the second handling direction are parallel or essentially parallel to one another. This makes a space-saving arrangement of the implant on the holding device and of the holding device on the storage unit possible.
The first connecting device preferably comprises at least one holding element which is designed to connect the implant to the holding device in the first connecting position of the first connecting device. Such a holding element can make only a one-time transfer of the first connecting device from the first connecting position into the first release position possible. Such a holding element can also make a change between the first connecting position and the first release position possible many times.
It is favorable when the at least one holding element is tongue-shaped. This makes an elastic movement of the holding element between the first connecting position and the first release position possible.
In addition or optionally, the at least one holding element can also be in the shape of a circular segment. As a result of this, implants, which have implant sections which are shaped in accordance with the circular segment shape of a holding element, may be connected to the holding device in a particularly reliable manner. A holding element in the shape of a circular segment can, in addition and where applicable, prevent any release of the implant from the holding device in a direction deviating from the first handling direction.
It is preferable when the at least one holding element can be moved and/or deformed within a holding plane. As a result of the movability and/or deformability of the at least one holding element within the holding plane, the amount of the first releasing force which is necessary for the transfer of the first connecting device from the first connecting position into the first release position can be defined in a particularly exact manner.
The holding plane is preferably at right angles or essentially at right angles to the holding axis. This makes it possible, in particular, in the case of an essentially elongated implant, for example, a bone screw to release this from the holding device in a first handling direction which is at right angles to the holding axis. As a result of this, it is possible for the implant and the holding device to be subjected to only a minimal frictional contact during transfer of the implant from the first holding position into the first release position.
It is favorable when the first connecting device has at least two holding elements. This makes it possible to introduce the first releasing force, which is required for transfer of the first connecting device from the first connecting position into the first release position, into at least two holding elements which are moved and/or deformed during the specified transfer. In this way, the mechanical load on the individual holding elements can be minimized.
The at least two holding elements can preferably be moved in opening directions opposite to one another in order to transfer the first connecting device from the first connecting position into the first release position. In this way, the first releasing force can be distributed uniformly onto the at least two holding elements.
In addition, it is preferable when the at least two holding elements can be moved in closing directions opposite to one another in order to transfer the first connecting device from the first release position into the first connecting position. This makes a gentle and self-centering transfer of the implant from the first release position into the first holding position possible.
It is particularly preferred when at least one holding element builds up a first restoring force, with which the first connecting device can be transferred back into the first connecting position, in order to form the first restoring device during transfer of the first connecting device from the first connecting position into the first release position. This can be ensured, for example, by selecting a corresponding material, for example, plastic so that the holding element is elastically deformable and can build up a first restoring force during deflection out of a basic position which corresponds to the first connecting position. As a result of this, a particularly simple construction of the first restoring device is ensured.
It is favorable when the at least one holding element limits an implant receptacle for accommodating the implant. As a result, the holding element contributes to an exact positioning of an implant on the holding device.
It is, in addition, favorable when the implant receptacle has an undercut. This makes a particularly reliable connection of the implant and the holding device possible.
It is advantageous when the implant receptacle is fully enclosed on its circumferential side. This makes a particularly reliable fixing of the implant to the holding device possible.
It is favorable when the first connecting device comprises at least one contact element which can abut on the implant in a tensioned manner in the first connecting position of the first connecting device. It is possible in a particularly simple manner with such a contact element for an implant to be secured in place on the holding device free from clearance without the first connecting device of the holding device needing to meet high tolerance requirements.
The contact segment advantageously limits the implant receptacle. As a result of this, a compact holding device can be created which makes a clearance-free connection of the holding device and implant possible.
It is advantageous when the at least one contact element is in the shape of a circular segment. Such a contact element may abut on a curved implant section particularly well, providing contact over a large surface area.
It is particularly preferred when the holding device has an indicating device which indicates an at least one-time transfer of the first connecting device from the first connecting position into the first release position. Such an indicating device makes it possible to ascertain without any doubt that an implant was connected to the holding device and has been released from the holding device. It can be concluded from this that this implant has been used during the course of an operation. This implant can be allocated with the aid of that holding device, the indicating device of which indicates the transfer of the first connecting device from the first connecting position into the first release position. It is understood that the indicating device described can also be provided in the case of holding devices which have only a first connecting device for releasably connecting the holding device and an implant and no second connecting device for releasably connecting the holding device and a storage unit.
The indicating device preferably comprises at least one indicating element which can be destroyed and/or plastically deformed during transfer of the first connecting device from the first connecting position into the first release position. This makes a particularly simple configuration of the indicating device possible.
It is preferred when the indicating device has at least one connecting section for the connection of at least two indicating elements and/or for the connection of the at least one indicating element to an additional part of the holding device, wherein the connecting section can be severed during transfer of the first connecting device from the first connecting position into the first release position. This makes a particularly simple construction of the indicating device possible. The connecting section can comprise, in particular, a predetermined breaking point or be formed by a predetermined breaking point.
It is favorable when the at least one indicating element is of a tape-like shape. This makes destruction and/or plastic deformation of the indicating element possible with the aid of relatively small destruction and/or deforming forces.
It is advantageous when the at least one indicating element has element sections which are movable relative to one another and extend in planes angled in relation to one another. In this way, the triggering force required for triggering the indicating device can be adjusted particularly well.
The at least one indicating element is favorably formed by a holding element. This makes a particularly simple construction of the holding device possible. In addition, it is ensured in a particularly reliable manner that the indicating device is also triggered when the first releasing force is applied in order to transfer the first connecting device from the first connecting position into the first release position.
It is favorable when the holding device comprises a plate-like basic member. The basic member makes a particularly compact configuration of the holding device possible.
It is preferred when the basic member extends in the holding plane. This makes a space-saving arrangement of the holding elements on the basic member possible.
In addition, it is preferred when the basic member extends at right angles or essentially at right angles to the holding axis. This makes a space-saving arrangement of an implant on the holding device possible as well as a space-saving arrangement of the holding device on the storage unit.
It is favorable when the at least one holding element and/or the at least one contact element and/or the at least one indicating element is or are arranged on the basic member. As a result of this, a particularly compact holding device can be created.
The at least one holding element and/or the at least one contact element and/or the at least one indicating element is or are preferably designed in one piece with the basic member. This makes a particularly inexpensive production of the holding device possible.
The holding device preferably comprises a data storage device for storing implant data. This makes a clear allocation of an implant connectable to the holding device and of the holding device possible. The implant data can relate, for example, to a producer, an article number, a batch number and/or to other properties of the implant. By reading the data storage device it is possible to be able to trace the implant data even when the implant has already been detached from the holding device. This makes it easier to trace which implant has been used during the course of an operation.
It is favorable when the data storage device is connected non-detachably to the holding device. This makes the allocation of the implant data to an implant connected to the holding device or detached from the holding device easier.
It is advantageous when the data storage device is writable several times. This makes it possible for the holding device to be used for different implants or for a group of different implants.
It is particularly preferred when the data storage device is designed to display the implant data in the form of an optical data storage device. This makes an optical identification of very small implants, in particular, possible which have, where applicable, no surface area which is large enough to display implant data.
It is favorable when the implant data are present in an alphanumeric form, as a barcode and/or as a matrix code. As a result, the implant data can be read directly without the aid of additional devices and/or can be detected easily, for example, with the aid of a scanner.
It is particularly preferred when the data storage device comprises a visible surface for the display of the implant data. This makes simple reading or scanning of the implant data possible.
It is particularly preferred when the visible surface is formed on the basic member and so the construction of the holding device is simplified further.
It is favorable when the implant data are designed to be in one piece with the holding device. As a result of this, a data storage device need not be made available separately. When the holding device is produced, for example, in an injection molding process, the implant data can be provided during the same production procedure as a result of corresponding configuration of the injection mold.
It is advantageous when the data storage device is designed in the form of an electronic data storage device. Such a data storage device makes it possible to store very extensive implant data, as well.
It is favorable when the data storage device comprises at least one RFID element. Such an element may be integrated inexpensively into the holding device or arranged on it, for example, by way of injection into a plastic material. In addition, an RFID element can be read without contact with the aid of a suitable reading device for reading the implant data.
It is favorable when the second connecting device comprises at least one connecting element which is designed to connect the holding device to the storage unit in the second connecting position of the second connecting device. The holding device can be connected reliably to the storage unit and easily detached from the storage unit with the aid of the at least one connecting element.
It is particularly preferred when the at least one connecting element comprises at least one snap-in element for forming a snap-in connection or is designed as a snap-in element, wherein the snap-in element is or can be brought into engagement interlockingly with the storage unit in the second connecting position of the second connecting device. Such a snap-in element makes a particularly reliable connection of the holding device and the storage unit possible. In addition, the transfer of the second connecting device from the second release position into the second connecting position can take place at the same time as a corresponding snap-in procedure of the snap-in element, whereby a good acoustic and/or optical indication conveys to an operator the fact that the second connecting device has reached its second connecting position.
The at least one connecting element can preferably be moved and/or deformed within a plane of connection. In this way, a second releasing force, which is possibly required for transfer of the second connecting device from the second connecting position into the second release position, can be defined exactly with respect to amount and/or direction.
The plane of connection is preferably parallel or essentially parallel to the holding axis of the implant. This makes a particularly simple construction of the second connecting device possible.
In addition, it is advantageous when the second connecting device has at least two connecting elements. As a result of this, the second releasing force, which is possibly required for transfer of the second connecting device from the second connecting position into the second release position, can be introduced into several connecting elements and so the mechanical load on the individual connecting elements is minimized.
The at least two connecting elements can preferably be moved in opening directions opposite to one another in order to transfer the second connecting device from the second connecting position into the second release position. This makes a comfortable handling of the holding device possible during the transfer of the second connecting device from the second connecting position into the second release position.
Furthermore, the at least two connecting elements can preferably be moved in closing directions opposite to one another in order to transfer the second connecting device from the second release position into the second connecting position. This makes a comfortable handling of the holding device possible during the transfer of the second connecting device from the second release position into the second connecting position.
It is favorable when the at least one connecting element builds up a second restoring force, with which the second connecting device can be transferred back into the second connecting position, for forming the second restoring device during transfer of the second connecting device from the second connecting position into the second release position. This makes a particularly simple construction of the second restoring device possible and this has the effect that the second connecting position of the second connecting device is the preferential position of the second connecting device.
The at least one connecting element preferably limits an undercut area for the accommodation of a section of the storage unit in the second connecting position of the second connecting device. As a result of this, a particularly reliable connection between the holding device and the storage unit is ensured.
It is preferred when the undercut area is limited by a contact surface of the basic member. In this way, an additional function associated with the second connecting device can be realized with the aid of the basic member.
It is advantageous when the second connecting device comprises at least one essentially U-shaped material section which has two legs of the U which extend parallel or essentially parallel to the holding axis and are connected to one another via a base of the U. Such a material section makes a simple arrangement and/or realization of at least one connecting element possible.
The holding axis is favorably arranged between two legs of the U. In this way, the implant can be protected from mechanical influences with the aid of the legs of the U when the implant is connected to the holding device.
Furthermore, it can be advantageous when the holding axis is arranged outside a space formed between the legs of the U. This makes a particularly compact construction of the second connecting device possible.
The second connecting device preferably comprises at least one actuating element for transferring the second connecting device from the second connecting position into the second release position. As a result of this, the holding device can be detached from the storage unit in a particularly simple manner.
The at least one actuating element is preferably designed in the form of a gripping section. As a result of this, the second connecting device can be actuated manually.
The at least one actuating element is arranged in an advantageous manner at a free end of a leg of the U. This makes a particularly simple transfer of the second connecting device from the second connecting position into the second release position possible.
Furthermore, the at least one actuating element is preferably arranged on the basic member. As a result of this, the handling of the holding device is made easier.
It is particularly preferred when at least one actuating element and at least one connecting element of the second connecting device are arranged on oppositely located sides of the basic member when looking along the holding axis of the implant. As a result of this, the second connecting device can be arranged relative to the storage unit in a space in the storage unit which is comparatively difficult to access but is well protected whereas the actuating element can be arranged on the oppositely located side of the basic member so as to be easily accessible.
The holding device preferably comprises at least one securing device which prevents any implantation of the implant when the implant is connected to the holding device. This has the advantage that an implant which is connected to the holding device cannot be used unintentionally together with the holding device during the course of an operation on a body part to be operated.
It is particularly favorable when the securing device comprises at least one securing section spaced from the holding axis. This makes it possible to protect a functional area of the implant, for example, a threaded section with the aid of the securing section so that this functional area cannot be brought into engagement with a body part to be operated.
The securing section is preferably arranged at an angle relative to the basic member, in particular, at right angles or essentially at right angles. This makes a particularly compact construction of the holding device possible. It is, in addition, favorable when the securing section is essentially C-shaped in a cross section at right angles to the holding axis. This allows a functional area of an implant to be protected over a particularly large surface area. In addition, the securing device allows an extensive mechanical protection of the implant.
In cross sections at right angles to the holding axis, the securing section is preferably larger in an area adjacent to the basic member than in an area removed from the basic member. This makes a particularly simple positioning of the holding device on the storage unit possible. In this respect, the holding device can be brought closer to the storage unit, first of all, with its area removed from the basic member and then be brought into abutment on the storage unit with the area adjacent to the basic member.
The securing section is favorably formed by the U-shaped material section of the second connecting device. As a result of this, it is possible to dispense with a separate securing section. With the aid of the base of the U of this material section, an implant connected to the holding device can also be protected against mechanical influences in a direction parallel to the holding axis.
It is favorable when the holding device has a guiding device, with which the holding device can be positioned relative to the storage unit. This makes the handling of the holding device easier when the holding device is connected to the storage unit.
It is favorable when the guiding device has at least one guiding section which is designed to abut on a section of the storage unit. The guiding section can be formed by parts of the holding device which have already been described, for example, by parts of the second connecting device and/or by a securing section of the securing device. The guiding device can, however, also have in addition or optionally at least one separate guiding section.
When the holding device comprises at least one implant, a structural module can be made available which can be connected to a storage unit. This structural module can be made available for an operation and sterilized again when not used and made available for the next operation.
Furthermore, it is suggested for a storage unit of the type described at the outset that the holding device have a second connecting device for releasably connecting the holding device and the storage unit. The storage unit makes the handling of at least one holding device easier and, therefore, also the handling of a very small implant, in particular, which is possibly connected to the holding device. It is particularly advantageous when the storage unit allows accommodation and/or securing in place of several holding devices.
It is preferred when the storage unit is designed for an orientation of at least two holding devices identical to one another. In this way, it is easier to find a specific holding device and, therefore, a specific implant.
Furthermore, it is preferred when the storage unit is designed for an orderly arrangement of at least three holding devices. This also makes it easier to find specific holding devices and specific implants.
A particularly neat arrangement of the holding device is achieved when the storage unit is designed for an arrangement of the holding devices in rows or columns. This makes a space-saving arrangement of several holding devices on the storage unit possible, in addition.
It is favorable when the storage unit comprises at least one receptacle for accommodating and/or securing at least one holding device in place. The relative position and/or location of the holding device relative to the storage unit can be defined with the aid of the receptacle.
It is particularly preferred when the at least one holding device can be inserted into the at least one receptacle at least in sections. As a result of this, the holding devices can be arranged on the storage unit in a space-saving manner and reliably connected to it.
The storage unit preferably comprises a plate for forming or for the arrangement of the at least one receptacle. This makes an inexpensive production of the storage unit possible which can, in addition, be cleaned particularly well.
The at least one receptacle is preferably limited by a section of the plate which can be connected to the second connecting device of the holding device. As a result of this, a storage unit which is constructed in a particularly simple manner can be created.
It is favorable when the receptacle has a cross section which predetermines the rotary position of a holding device about its holding axis relative to the storage unit. In this way, the rotary position of the holding device can be predetermined and so the ease, with which this holding device and, therefore, a specific implant can be found, is improved.
It is particularly favorable when the at least one receptacle has a cross section in the form of an elongated hole. As a result of this, a preferential orientation of the holding device relative to the storage unit can be predetermined in a simple manner.
It is advantageous when the receptacle has at least one storage element projecting from the plate for connecting the storage unit to the second connecting device of a holding device. A particularly reliable connection between the holding device and the storage unit can be provided with the aid of such a storage element.
It is favorable when the storage unit has at least one spacer device which spaces the plate in relation to a mounting surface for the storage unit. This makes it possible to create a distance between the plate and the mounting surface, in which at least sections of the holding devices and/or the implants can be arranged without them coming into contact with the mounting surface.
It is preferred when the spacer device comprises a frame extending along the edge of the plate at least in sections. As a result of this, the storage unit can be placed on the mounting surface in a manner particularly secure against any tilting. When the frame extends along the entire edge of the plate, a space extending between the plate of the storage unit and the mounting surface, in which holding devices can be arranged at least in sections, is protected particularly well from mechanical influences.
A structural module consisting of a storage unit with at least one holding device makes it possible for holding devices and/or implants required for a specific operation to be made available in an orderly manner and without additional preparation steps. This structural module can be replenished after an operation, sterilized and made available for a subsequent operation.
The following description of preferred embodiments of the invention serves to explain the invention in greater detail in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
These show:
FIG. 1 : a perspective view of a storage unit and a plurality of holding devices which are connected to the storage unit or released from it as well as a plurality of implants which are each connected to a holding device;
FIG. 2 : a perspective view of a holding device according to a first embodiment;
FIG. 3 : an exploded view of the holding device according to FIG. 2 , an implant as well as a section of the storage unit according to FIG. 1 ;
FIG. 4 : a perspective view of the parts illustrated in FIG. 3 , wherein the implant is releasably connected to the holding device, wherein the holding device is releasably connected to the storage unit;
FIG. 5 : a view corresponding to FIG. 4 , wherein the implant is released from the holding device with the aid of a removing tool;
FIG. 6 : a perspective view of a holding device according to a second embodiment and a section of the storage unit according to FIG. 1 ;
FIG. 7 : a view of the holding device according to FIG. 6 from a perspective turned through approximately 90° in relation to FIG. 6 ;
FIG. 8 : a perspective view of a holding device according to a third embodiment;
FIG. 9 : a view of the holding device according to FIG. 8 from a perspective turned through approximately 90° in relation to FIG. 8 ;
FIG. 10 : a perspective view of a holding device according to a fourth embodiment;
FIG. 11 : a view of the holding device according to FIG. 10 from a perspective turned through approximately 180° in relation to FIG. 10 ;
FIG. 12 : a perspective view of a holding device according to a fifth embodiment;
FIG. 13 : a view of the holding device according to FIG. 12 from a perspective turned though approximately 120° in relation to FIG. 12 ;
FIG. 14 : a perspective view of a holding device according to a sixth embodiment;
FIG. 15 : a view of the holding device according to FIG. 14 from a perspective turned through approximately 150° in relation to FIG. 14 ;
FIG. 16 : a perspective view of a holding device according to a seventh embodiment;
FIG. 17 : a view of the holding device according to FIG. 16 from a perspective turned through approximately 150° in relation to FIG. 16 ;
FIG. 18 : a perspective view of a holding device according to an eighth embodiment;
FIG. 19 : a view of the holding device according to FIG. 18 from a perspective turned through approximately 90° in relation to FIG. 18 ;
FIG. 20 : a perspective view of a holding device according to a ninth embodiment; and
FIG. 21 : a view of the holding device according to FIG. 20 from a perspective turned through approximately 150° in relation to FIG. 20 .
DETAILED DESCRIPTION OF THE INVENTION
The same or functionally equivalent elements are designated in all the Figures with the same reference numerals.
In FIG. 1 , a storage unit which is designed for the arrangement of holding devices for implants is designated altogether with the reference numeral 2 . It has a rectangular plate 4 , the plate thickness of which is a few millimeters. A spacer device designated altogether with the reference numeral 8 extends along the edge 6 of the plate 4 . The spacer device is designed in the form of a frame 10 which comprises four walls 12 arranged in respective pairs at right angles to one another and connected to one another. The walls 12 extend at right angles to the plate 4 and space this from a mounting surface 14 , on which the storage unit 2 is placed.
The plate 4 has a plurality of receptacles 16 which are each formed by openings provided in the plate 4 . The receptacles 16 are distributed over the plate 4 in a regular manner and arranged in rows 18 which are parallel to one another and columns 20 at right angles thereto. The receptacles 16 are each designed in the form of an elongated hole, wherein the longer cross-sectional axis (without any reference numeral) extends in the direction of the rows 18 and the shorter cross-sectional axis (without any reference numeral) in the direction of the columns 20 .
The plate 4 has altogether 56 receptacles 16 arranged in seven rows 18 and eight columns 20 . The cross sections 22 of the receptacles 16 are of the same size and oriented identically to one another. Each receptacle 16 is limited by sections 24 of the plate 4 . More details concerning the function of the sections 24 will be explained further on.
One of the receptacles 16 illustrated in FIG. 1 comprises two elongated storage elements 26 . They project from an upper side 28 of the plate 4 and extend in the direction of the rows 18 . The storage elements 26 comprise two storage sections 30 which are spaced from the upper side 28 , extend parallel to the plate 4 and limit storage areas 32 extending in the direction of the rows 18 together with the upper side 28 of the plate 4 . The function of the storage areas 32 will also be explained in detail further on.
The storage unit 2 serves to accommodate and/or secure in place a plurality of holding devices which can be releasably connected to the receptacles 16 of the plate 4 . In FIG. 1 , various holding devices are illustrated which are releasably connected to the storage unit 2 , namely holding devices 34 (cf. FIGS. 4 and 5 ), holding devices 36 (cf. FIGS. 6 and 7 ), holding devices 38 (cf. FIGS. 8 and 9 ) and holding devices 40 (cf. FIGS. 10 and 11 ). In FIG. 1 , one of the holding devices 38 is illustrated in its state detached from the storage unit 2 .
Each of the holding devices 34 , 36 , 38 , 40 serves for the arrangement of an implant 42 designed in the form of a screw. Each implant 42 can, as illustrated in FIG. 1 , be releasably connected to one of the holding devices 34 , 36 , 38 , 40 .
The holding device 34 comprises a first connecting device 44 for releasably connecting the holding device 34 and an implant 42 as well as a second connecting device 46 for releasably connecting the holding device 34 and the storage unit 2 .
The holding device 34 defines a holding axis 48 , along which an implant 42 can be arranged when the implant 42 is connected to the holding device 34 and takes up a holding position (cf. FIG. 4 ). This position of the implant 42 will be designated in the following as first holding position.
A holding plane 50 , in which an approximately square, plate-like basic member 52 extends, runs at right angles to the holding axis 48 . This basic member has a visible surface 54 on the side located opposite the second connecting device 46 . The basic member 52 has a contact surface 56 on its side located opposite the visible surface 54 .
The first connecting device 44 comprises an implant receptacle 58 which extends in the area of the holding axis 48 at the height of the holding plane 50 . The implant receptacle 58 is limited by a contact section 60 which is approximately semi-cylindrical and is formed by the basic member 52 . The contact section 60 is adjoined by two holding elements 62 which are tongue-shaped and arranged so as to be located opposite one another. They have at their free ends snap-in projections 64 which face one another. The snap-in projections 64 limit the implant receptacle 58 in such a manner that an undercut results.
The basic member 52 has elongated spaces 66 and 68 , respectively, on the sides of the respective holding elements 62 facing away from the implant receptacle 58 . The spaces 66 and 68 have the effect that the holding elements 62 may be moved elastically in the holding plane 50 . The holding elements 62 can be moved in an opening direction 70 into the respective spaces 66 and 68 . The holding elements 62 can also each be moved in the direction towards the implant receptacle 58 in closing directions 72 which point towards one another.
The holding elements 62 are illustrated in FIG. 2 in a first connecting position of the first connecting device 44 . When the holding elements 62 are deflected out of this first connecting position into the spaces 66 and 68 as a result of a first releasing force being applied, the first connecting device 44 can be transferred into a first release position. During such a transfer of the first connecting device 44 from the first connecting position into the first release position, the holding elements 62 are elastically deformed and deflected into the spaces 66 and 68 . As a result of this, the holding elements 62 each build up a first restoring force which is directed towards the implant receptacle 58 . The first restoring forces have the effect that the holding elements return to the position illustrated in FIG. 2 of their own accord following deflection into the spaces 66 and 68 . In this way, the holding elements 62 form a first restoring device 73 .
The basic member 52 comprises a data storage device designated altogether with the reference numeral 74 . In the case of the holding device 34 , the data storage device 74 comprises the visible surface 54 of the basic member 52 . On the visible surface 52 , implant data 76 are arranged which are raised above the visible surface 52 and serve to identify an implant 42 which can be connected to the holding device 34 via the first connecting device 44 . The implant data 76 are alphanumeric.
The second connecting device 46 , with which the holding device 34 can be connected to the storage unit 2 , comprises a connecting element 78 in the form of a curved snap-in element 80 . Together with the contact surface 56 of the basic member 52 , the snap-in element 80 limits an undercut area 82 , in which a section 24 of the plate 4 of the storage unit 2 , which is also illustrated in FIGS. 1 , 3 and 4 , can be arranged.
The connecting element 78 is illustrated in FIG. 2 in a second connecting position of the second connecting device 46 . When the connecting element 78 is deformed out of this second connecting position in the direction towards the holding axis 48 as a result of a second releasing force being applied, the first connecting device 44 can be transferred into a second release position. During such a transfer of the second connecting device 46 from the second connecting position into the second release position, the connecting element 78 is elastically deformed. As a result of this, the connecting element 78 builds up a second restoring force which is directed away from the holding axis 48 . This second restoring force has the effect that the connecting element 78 returns back to the position illustrated in FIG. 2 of its own accord following its deformation in the direction towards the holding axis 48 . In this way, the connecting element 78 forms a second restoring device 81 .
The holding device 34 comprises a guiding device 84 which has two flat guiding sections 86 which extend parallel to the holding axis 48 . The guiding sections 86 serve to position the holding device 34 relative to a receptacle 16 of the storage unit 2 .
The holding device 34 comprises, in addition, a securing device 88 which comprises a securing section 90 which is C-shaped in cross sections at right angles to the holding axis 48 . The securing section 90 has two slits 92 which extend parallel to the holding axis 48 and are approximately rectangular. The securing section 90 has, in addition, a free end 94 on its side facing away from the basic member 52 . The cross sections of the securing section 90 at right angles to the holding axis increase in size from this free end, when seen in the direction of the holding axis 48 , as far as the level of two steps 96 . As a result of this, the cross section of the securing device 88 is greater in an area adjacent to the basic member 52 than in an area at a distance from the basic member 52 .
In FIG. 3 , the holding device 34 is illustrated with an implant 42 . The implant 42 is in a position released from the holding device 34 .
The implant 42 extends along an implant axis 98 . It has a first implant section 100 in the form of a screw head. This is adjoined by a short cylindrical implant section 102 . Finally, the implant 42 has an implant section 104 which is provided with an external thread 106 . The implant 42 can be secured to a body part to be operated with the aid of the external thread 106 .
In order to connect the implant 42 to the holding device 34 , the implant section 102 of the implant 42 can be positioned at the level of the holding plane 50 to the side in relation to the holding device 34 . This position of the implant 42 is designated in the following as first release position. The implant 42 can be moved from this position into the implant receptacle 58 within the holding plane 50 in a connecting direction which is designated as 108 and is at right angles to the holding axis 48 . In this respect, the holding elements 62 are moved away from one another by the implant section 102 in opening directions 70 opposite to one another until the snap-in projections 64 engage interlockingly around the implant section 102 (cf. FIG. 4 ).
When the implant 42 takes up its first holding position on the holding device 34 , which is illustrated in FIG. 4 , the implant section 100 extends beyond the visible surface 54 of the basic member 52 . The implant section 102 is held in the implant receptacle 58 . The implant section 104 is surrounded by the securing section 90 C-shaped in cross section at right angles to the holding axis 48 .
The holding device 34 can be brought from a second release position illustrated in FIG. 3 into a position illustrated in FIG. 4 , in which the holding device 34 is connected to the storage unit 2 . This position of the holding device 34 is designated in the following as second holding position.
In order to bring the holding device 34 into the second holding position proceeding from the second release position, the free end 94 of the securing section 90 of the holding device 34 can be introduced into one of the receptacles 16 of the plate 4 of the storage unit 2 . In this respect, the holding device 34 is moved in a connecting direction designated in FIG. 3 with the reference numeral 110 until the snap-in element 80 engages interlockingly behind the section 24 of the plate 4 and the contact surface 56 of the basic member 52 abuts on the upper side 28 of the plate 4 (cf. FIG. 4 ).
In FIG. 4 , the first connecting device 44 is in the first connecting position. The implant 42 is connected to the holding device 34 and is in the first holding position.
In FIG. 4 , the second connecting device 46 is in the second connecting position. The holding device 34 is connected to the storage unit 2 and is in the second holding position.
The arrangement illustrated in FIG. 4 makes it easy for a surgeon to handle the implant 42 since it is connected to the holding device 34 and this is, on the other hand, connected to the storage unit 2 . In this respect, the implant 42 can be identified clearly with the aid of the data storage device 74 .
In order to bring the implant 42 from its first holding position illustrated in FIG. 4 into the first release position illustrated in FIG. 5 , a removing tool 112 can be used. The removing tool 112 has a tool head 114 which is designed to engage around the implant section 104 . The removing tool 112 can be formed by a screwdriver which can also be used for screwing the external thread 106 of the implant 42 into a body part to be treated.
In order to bring the first connecting device 44 from its first connecting position illustrated in FIG. 4 into the first release position, the removing tool 112 can be moved such that the implant 42 is handled in a first handling direction, which is designated in FIG. 5 as 116 , in a direction at right angles to the holding axis 48 so that the implant section 102 is moved out of the implant receptacle 58 within the holding plane 50 . In this respect, a first releasing force must be applied and this is determined by the resistance of the holding elements 62 which move within the holding plane 50 in opening directions 70 (cf. FIG. 3 ) into the adjoining spaces 66 and 68 for the release of the implant section 102 .
As soon as the implant 42 has been moved out of the implant receptacle 58 to such an extent that it takes up the first release position, the implant 42 can be removed from the holding device 34 in a direction parallel to the holding axis 48 . In this respect, the holding device 34 remains on the plate 4 of the storage unit 2 . This is due to the fact that the second connecting device 46 can be actuated independently of the first connecting device 44 . The first connecting device 44 is transferred from the first connecting position into the first release position by the first releasing force being applied. In this respect, the second connecting device 46 remains in the second connecting position illustrated in FIGS. 4 and 5 and so the holding device 34 remains connected to the storage unit 2 .
In order to transfer the second connecting device 46 into the second release position so that the holding device 34 can be released from the storage unit 2 , the holding device 34 can be handled in a handling direction 118 in a direction parallel to the holding axis 48 and moved out of the receptacle 16 of the plate 4 . For this purpose, a pressure force can be applied, for example, from the free end 94 of the securing section 90 in the direction of the second handling direction 118 . As a result of this, a second releasing force can be applied which deforms the connecting element 78 in the direction of the holding axis 48 whilst abutting on the section 24 of the plate 4 so that the second connecting device 46 is transferred from the second connecting position into the second release position. As a result of this, the holding device 34 can be released from the plate 4 .
The first handling direction 116 and the second handling direction 118 extend at right angles to one another. It is understood that the transfer of the first connecting device 44 from the first connecting position into the first release position can be aided by tilting of the implant 42 through an angle of tilt 120 relative to the holding axis 48 . In this case, the first handling direction 116 and the second handling direction 118 can be oriented at an angle to one another which corresponds to a right angle plus the angle of tilt 120 .
The holding device 36 illustrated in FIGS. 6 and 7 has a construction similar to that of the holding device 34 . In the following, only the differences between the holding devices 34 and 36 will be explained in detail. In contrast to the holding device 34 , the holding device 36 has not only a connecting element 78 in the form of a curved snap-in element 80 but also two connecting elements 122 and 124 which are arranged opposite one another. They extend parallel to the holding axis 48 and are connected to the securing section 90 at the free end 94 of the holding device 36 .
The connecting elements 122 and 124 each have a snap-in element 126 and 128 , respectively, at their ends facing the basic member 52 of the holding device 36 . These snap-in elements are arranged at the same level as the snap-in element 80 when seen along the holding axis 48 . The connecting elements 122 and 124 are movable and deformable on their own and also relative to one another within a connecting plane 130 such that the snap-in elements 126 and 128 can be moved towards one another within the connecting plane 130 in opening directions 132 opposite to one another. As a result of this, the second connecting device 46 of the holding device 36 can be transferred from its second connecting position illustrated in FIG. 6 into the second release position. When the connecting elements 122 and 124 are spaced so near to one another in the area of the snap-in elements 126 and 128 that the snap-in elements 126 and 128 can be disengaged from the section 24 of the plate 4 , the holding device 36 can be brought from the second holding position into the second release position (cf. FIG. 7 ) in a second handling direction 118 parallel to the holding axis 48 .
Once the connecting elements 122 and 124 and the snap-in elements 126 and 128 have been disengaged from the receptacle 16 of the plate 4 , the connecting elements 122 and 124 move back again in closing directions 134 opposite to one another of their own accord within the connecting plane 130 such that in the second release position of the holding device 36 the second connecting device 46 is again transferred into the second connecting position. In order to be able to connect the holding device 36 to the storage unit 2 again, the free end 94 of the securing section 90 can be introduced into the receptacle 16 until beveled run-on surfaces 136 and 138 formed by the snap-in elements 126 and 128 engage with the sections 24 of the plate 4 . As a result of this, the connecting elements 122 and 124 are moved towards one another in opening directions 132 so that the second connecting device 46 is transferred into the second release position. The beveled run-on surfaces 136 and 138 are introduced into the receptacle 16 to such an extent that the snap-in elements 126 and 128 engage interlockingly behind the section 24 of the plate 4 and, therefore, the second connecting device 46 again takes up the second connecting position.
The holding device 38 illustrated in FIGS. 8 and 9 has a construction similar to that of the holding device 36 . In the following, only the differences between the holding devices 36 and 38 will, therefore, be explained in detail. The connecting elements 122 and 124 of the holding device 38 which extend parallel to the holding axis 48 are not connected to the securing section 90 at the free end 94 thereof but rather via attachments 140 and 142 which are provided adjacent to the connecting element 78 . The snap-in elements 126 and 128 are not designed in the form of projections, as in the holding device 36 according to FIGS. 6 and 7 , but are formed by edge surfaces of the connecting elements 122 and 124 pointing in the direction towards the contact surface 56 of the basic member 52 . The connecting elements 122 and 124 have, in addition, two edge sections 144 and 146 which are slightly inclined in their course relative to the holding axis 48 and make the introduction of the free end 94 into a receptacle 16 of the plate 4 easier.
In order to be able to position the holding device 38 exactly relative to a receptacle 16 of the plate 4 of the storage unit 2 , the holding device 38 has guiding sections 148 and 150 which extend parallel to the holding axis 48 proceeding from the contact surface 56 and each abut on a section 24 of the plate 4 in the second holding position of the holding device 38 .
The holding device 40 illustrated in FIGS. 10 and 11 differs, inter alia, from the holding devices 34 , 36 and 38 described thus far in that it defines a holding axis 48 which does not essentially extend centrally through the basic member 52 but is offset to the side in relation thereto. This has the advantage that a particularly large visible surface 54 results, on which a relatively large number of implant data 76 can be displayed closely adjacent to one another but easy to read.
The implant receptacle 58 of the holding device 40 , which is limited by two holding elements 62 located opposite one another as well as the contact section 60 of the basic member 52 , is offset to such an extent out of the center of the basic member 52 that the space 68 present in the case of the holding devices 34 , 36 and 38 is no longer applicable or is formed by the surroundings of the holding device 40 .
The second connecting device 46 of the holding device 40 comprises, in a similar way to the holding devices 36 and 38 , two connecting elements 122 and 124 extending essentially parallel to the holding axis 48 . In contrast to the holding devices 36 and 38 , the connecting elements 122 and 124 of the holding device 40 are provided separate from the securing section 90 of the securing device. A first connecting element 122 is designed, for example, as a leg 152 of a U which extends parallel to the holding axis 48 proceeding from the contact surface 56 of the basic member 52 as far as the free end 94 of the securing section 90 . Here, the leg 152 of the U merges into a base 154 of the U which extends parallel to the basic member 52 and, therefore, to the holding plane 50 . At its end located opposite the leg 152 of the U the base 154 of the U ends at a leg 156 of the U which forms the connecting element 124 . The legs 152 and 156 of the U and the base of the U together form a U-shaped material section 158 . The leg 156 of the U extends from the base 154 of the U approximately parallel to the holding axis 48 in the direction towards the basic member 52 and—in the area of a free end 160 which is not connected to the basic member 52 —as far as an actuating element 162 . The actuating element 162 is designed in the form of a gripping section. This gripping section and the connecting elements 122 and 124 are arranged on oppositely located sides of the basic member 52 when seen along the holding axis 48 .
In order to connect the holding device 40 illustrated in FIGS. 10 and 11 to the storage unit 2 illustrated in FIG. 1 , the free end 94 of the holding device 40 can be inserted into one of the receptacles 16 of the plate 4 . The second connecting device 46 of the holding device 40 is hereby transferred from the second connecting position into the second release position with deformation of the connecting element 124 in the direction towards the holding axis 48 which corresponds to an opening direction 132 . When the holding device 40 is inserted into one of the receptacles 16 to such an extent that the snap-in elements 126 and 128 can engage interlockingly behind associated sections 24 of the receptacle 16 , the connecting element 124 springs back into the position illustrated in FIG. 10 in accordance with a closing direction 134 so that the second connecting device 46 is transferred into the second connecting position.
In order to transfer the second connecting device 46 from the second connecting position into the second release position, the actuating element 162 can be actuated in accordance with the opening direction 132 which extends at right angles to the holding axis 48 . In this respect, the connecting element 124 or rather the leg 156 of the U is deformed within a connecting plane 130 so that the snap-in element 128 can disengage from the associated section 24 of the plate 4 , whereby the second connecting device 46 is transferred into the second release position. In this way, the holding device 40 can be released from the storage unit 2 during its movement in accordance with a second handling direction 118 which extends parallel to the holding axis 48 .
The legs 152 and 156 of the U of the holding device 40 are arranged on oppositely located sides relative to the holding axis 48 . This has the advantage that an implant 42 connected to the holding device 40 via the first connecting device 44 is protected from mechanical influences not only by the securing section 90 but also with the aid of the U-shaped material section 158 . In this respect, the base 154 of the U shields the implant 42 in relation to the mounting surface 14 illustrated in FIG. 1 when the holding device 40 is connected to the storage unit 2 .
FIGS. 12 and 13 illustrate an additional holding device 164 . This likewise comprises a U-shaped material section 158 . In contrast to the holding device 40 according to FIGS. 10 and 11 , the holding axis 48 of the holding device 164 extends approximately centrally through the basic member 52 . In addition, the holding elements 62 of the first connecting device 44 are oriented in such a manner that their opening and closing directions 70 and 72 do not extend parallel to the opening directions 132 and closing directions 134 of the connecting elements 122 and 124 , as in the case of the holding device 40 , but rather at right angles to one another.
The holding device 164 has, in addition, an actuating element 166 which is rigidly connected to the basic member 52 , projects beyond the visible surface 54 and extends approximately parallel to the holding axis 48 . The actuating elements 162 and 166 are arranged on oppositely located sides of the holding axis 48 and can be moved relative to one another in the specified opening directions 132 and closing directions 134 , respectively, in order to transfer the second connecting device 46 from the second connecting position into the second release position.
The basic member 52 has a reduced material thickness in a central section 168 . The central section 168 has a surface 170 which extends parallel to the visible surface 54 of the basic member 52 and is spaced at a smaller distance from the contact surface 56 of the basic member 52 than the visible surface 54 . As a result of this, the surface 170 is set back in comparison with the visible surface 54 . When the holding device 164 is connected to an implant 42 with the aid of its first connecting device 44 , an implant section 100 (cf. FIG. 3 ) does not extend beyond the visible surface 54 or only slightly. As a result of this, the holding device 164 and an implant 42 can be supplied together to an inscription device, with which implant data 76 can be applied to the visible surface 54 of the holding device 164 , for example, by way of overprinting.
The holding device 164 illustrated in FIGS. 12 and 13 differs, in addition, from the holding device 40 illustrated in FIGS. 10 and 11 in that its U-shaped material section 158 has insertion aids 172 and 174 . The insertion aid 172 comprises an insertion surface 176 extending at a slight angle to the holding axis 48 . The insertion aid 174 is formed by a partially cylindrical transition section between the base 154 of the U and the leg 156 of the U. The insertion aids 172 and 174 make the insertion of the holding device 164 into a receptacle 16 of the storage unit 2 easier.
FIGS. 14 and 15 illustrate a further holding device 180 . This differs from the holding devices 40 and 164 due to the fact that its U-shaped material section 158 is designed in such a manner that the legs 152 and 156 of the U are immediately adjacent to one another. The holding axis 48 of the holding device 180 extends outside a space 181 formed between the legs 152 and 156 of the U.
The basic member 52 of the holding device 180 has a recess 182 extending within the holding plane 50 . This creates a space for movement of the leg 156 of the U which can be moved in opening direction 132 or in closing direction 134 with the aid of the actuating element 162 .
The implant receptacle 58 of the first connecting device 44 of the holding device 180 differs from the implant receptacles of the holding devices 34 , 36 , 38 , 40 , 164 described thus far in that the holding elements 62 which are located opposite one another are comparatively short. Instead of a rigid contact section 60 (cf. FIG. 2 ), the implant receptacle 58 of the holding device 180 has contact elements 184 in the shape of circular segments. They are of a lug-shaped design and connected to the basic member 52 at the level of the visible surface 54 thereof. The contact elements 184 extend at an angle in the direction towards the holding axis 48 proceeding from the visible surface 54 .
When an implant 42 is connected to the holding device 180 with the aid of the first connecting device 44 , the contact elements 184 abut on the implant section 102 (cf. FIG. 3 ) under tension. As a result of this, the implant 42 is connected to the holding device 180 without any clearance.
The holding device 180 comprises an indicating device 186 , with which it can be shown whether the first connecting device 44 of the holding device 180 has been transferred from the first connecting position into the first release position at least once. The indicating device 186 comprises two tape-like indicating elements 188 which extend adjacent to the implant receptacle 58 within the holding plane 50 . The indicating elements 188 are connected to one another via a connecting section 190 which forms a predetermined breaking point.
When an implant 42 connected to the holding device 180 is transferred from a first holding position into a first release position in a direction at right angles to the holding axis 48 in accordance with a first handling direction 116 , this causes destruction of the connection between the indicating elements 188 . As a result of this, it can be clearly ascertained that an implant 42 has already been removed from the holding device 180 . As a result of this, any unintentional re-use of the holding device 180 can also be ruled out.
FIGS. 16 and 17 illustrate an additional holding device 192 which differs from the holding device 180 according to FIGS. 14 and 15 only in its configuration of the indicating device 186 . The indicating device 186 of the holding device 192 comprises two element sections 194 and 196 which are arranged at an oblique angle to one another. The element section 194 is articulated to a closed edge 198 of the basic member 52 and extends at an acute angle relative to the visible surface 54 of the basic member 52 in the direction towards the holding axis 48 . The element section 196 extends in the direction towards the holding axis 48 as far as adjacent to the implant receptacle 58 proceeding from the end of the element section 194 facing the holding axis 48 .
When an implant 42 held on the holding device 192 is transferred from a first holding position into a first release position in a first handling direction 116 , the element sections 194 and 196 are deformed permanently and so it can be shown that the first connecting device 44 of the holding device 192 has been transferred from the first connecting position into the first release position.
The holding device 200 illustrated in FIGS. 18 and 19 differs from the holding devices 180 and 192 in its configuration of the first connecting device 44 . This likewise comprises contact elements 184 which are in the shape of circular segments but no essentially tongue-shaped holding elements 62 but rather holding elements 202 which are shaped like circular segments and limit an implant receptacle 58 , which is completely enclosed on its circumferential side and extends within a holding plane 50 , together with the contact elements 184 . The holding elements 202 are connected to one another via a connecting section 190 which forms a predetermined breaking point.
An implant 42 can be inserted into the holding device 200 in that it is inserted into the implant receptacle 58 in the direction of the holding axis 48 with its implant section 104 (cf. FIG. 3 ) first. In this respect, the contact elements 184 and the holding elements 202 are deformed radially outwards by the external thread 106 so that the implant section 104 can be introduced into the implant receptacle completely until the implant section 102 is arranged at the level of the contact elements 184 and the holding elements 202 and the contact elements 184 and the holding elements 202 can be reset again radially inwards. The connecting device 44 then takes up the first connecting position.
In order to release the implant 42 from the holding device 200 , the first connecting device 44 can be brought from the first connecting position into the first release position in that the implant 42 is moved out of the implant receptacle 58 in a first handling direction designated as 116 . In this respect, the connecting section 190 between the holding elements 202 is destroyed. As a result of this, it can be shown that an implant 42 was already held on the holding device 200 and so any unintentional re-use of the holding device 200 can be ruled out. The holding device 200 therefore likewise comprises an indicating device 186 . With this indicating device, the indicating elements are formed by the holding elements 202 .
FIGS. 20 and 21 illustrate a further holding device 204 . Its first connecting device 44 has a construction which corresponds, for example, to the construction of the first connecting device 44 of the holding device 34 according to FIG. 2 . The holding device 204 likewise has a securing section 90 which corresponds in its construction to the securing section 90 of the holding device 40 according to FIGS. 10 and 11 .
On the other hand, the second connecting device 46 of the holding device 204 differs from the second connecting devices 46 of the holding devices 34 , 36 , 38 , 40 , 164 , 180 , 192 , 200 due to the fact that the snap-in elements 126 and 128 are arranged on the side of the connecting elements 122 and 124 facing the holding axis 48 . This causes a reversal of the corresponding opening directions 132 and the closing directions 134 . In addition, an undercut area 82 formed between the snap-in elements 126 and 128 and the contact surface 56 of the basic member 52 is formed between the connecting elements 122 and 124 and not on oppositely located sides.
The holding device 204 can be connected to the storage unit 2 illustrated in FIG. 1 in that the securing section 90 of the holding device 204 dips into a receptacle 16 of the plate 4 until the snap-in elements 126 and 128 engage in the storage areas 32 of the storage elements 26 . The second connecting device 46 of the holding device 204 then takes up the second connecting position.
In order to transfer the second connecting device 46 of the holding device 204 into the second release position, the actuating elements 162 of the connecting elements 122 and 124 can be moved towards one another in actuating directions 206 opposite to one another so that the snap-in elements 126 and 128 are moved away from one another in opening direction 132 and disengage from the storage areas 32 of the storage elements 26 .
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In order to improve a holding device for an implant, comprising a first connecting device for releasably connecting the holding device and the implant, such that very small implants, in particular, are easy to handle, it is suggested that the holding device have a second connecting device for releasably connecting the holding device and a storage unit.
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BACKGROUND OF THE INVENTION
The present invention relates to a method enabling multiple-antenna equalization in a radioelectrical receiver, enabling the reception of a digital radioelectrical signal of the series linear modulation type (or the like) on at least two antennas in the presence of several propagation paths, also called multiple paths, or in the presence of interfering sources also called jammers.
The invention also relates to a multiple-antenna radioelectrical receiver using such a method.
It can be applied especially to the implementation of HF transmission systems and of the base stations of GSM mobile radio communications systems.
In these systems, the transmitted signal comes from the phase and/or amplitude modulation of a carrier on a sequence of symbols of which a portion, known to the receiver, are called "learning sequences".
The channel may be that of transmissions in the high frequency (HF) range enabling long-distance communications (at distances of hundreds to thousands of kilometers). The multiple paths of the HF channel are due to the multiple reflections of the signal on the ionospheric layers of the atmosphere and on the ground. The channel may also be that of transmissions in the UHF or ultra-high frequency range used in mobile radio communications (for example GSM communications). The multiple paths of the mobile radio channel are due to multiple reflections on the surfaces of buildings and on terrestrial surface features.
As for jamming, it may be deliberate (wideband jamming for example) or involuntary (by other transmission signals using the same frequency band).
In many systems presently in operation, the matching with the characteristics of the transmission channel is made possible by the insertion, in the waveform, of learning sequences known to the receiver. There are then various possible ways to obtain the adaptive equalization of the useful signal received. Several approaches are described for example in the article by J. J. Proakis entitled "Adaptive equalization for TDMA digital mobile radio", IEEE Trans. on Vehicular Technology, Vol. 40, No. 2, May 1991. The processing referred to is a form of equalization based on the Viterbi algorithm associated with an estimation of the transmission channel by means of learning sequences. This approach is commonly used in GSM systems.
In the context of HF transmissions at high bit rates (2400 bauds), less complex approaches are preferred. These less complex approaches are provided by a simplified version of the Viterbi algorithm, the M-algorithm described in particular in an article by A. Baier and G. Heinrich entitled "Performance Of M-algorithm MLSE Equalizers In Frequency-Selective Fading Mobile Radio Channels", Proc. of 1989 International Conference on Communications, ICC'89, or again by a decision feedback equalizer or FE. This may be obtained by means of self-adaptive filters adapted by a recursive least-error squares type algorithm in preference to a gradient algorithm for reasons of speed of convergence, or it may be computed from an estimation of the transmission channel as in the article by P. K. Shukla and L. F. Turner, "Channel-Estimation-Based Adaptive DFE For Fading Multipath Radio Channels", IEEE Proceedings-I, Vol. 138, No. 6, December 1991.
When there is "fading", the variation of the power of the signals received leads to a deterioration of the performance characteristics in terms of the binary error rate (BET). The use of several antennas in equalizers with a diversity of antennas enables compensation for deterioration by taking advantage of the difference between the transmission channels corresponding to the different antennas.
In the presence of jamming, these equalization techniques become soon inefficient and specific anti-jamming techniques are necessary. These are, for example, error correction encoding, the excision of jamming by notch filtering, or the use of frequency hopping links. These techniques are used in many operational systems but are nevertheless limited when the interference phenomena are strong and occupy the entire band of the useful signal. It thus becomes appropriate to use anti-jamming means of greater efficiency, based on the use of antenna filtering techniques.
Antenna filtering techniques appeared in the early '60s. A summary description of these techniques is given in the doctoral thesis by P. Chevalier, "Antenne adaptative: d'une structure lineaire a une structure non lineaire de Volterra" ("Adaptive antennas: from a linear structure to a non-linear Volterra structure"), Universite de Paris Sud, June 1991. These techniques are designed to combine the signals received by the different sensors constituting the antenna so as to optimize its response to the scenario involving useful signals and jammers.
Since the conditions of propagation and jamming may change in the course of time, it is necessary to be able to adapt the antenna in real time to these variations by the use of a special antenna filtering technique known as the "adaptive antenna" technique. An adaptive antenna is an antenna that detects interference sources automatically by constructing holes in its radiation pattern in the direction of these interferences while at the same time improving the reception from the useful source, without any prior knowledge about the interferences and using minimum information on the useful signal Furthermore, through the tracking capacity of the algorithms used, an adaptive antenna is capable of automatic response to a changing environment.
Until very recently, it was always envisaged, in transmission systems, to have operation independent of the single sensor and adaptive antenna based techniques of adaptive equalization. This leads to sub-optimal performance characteristics. Thus, the system described by R. Dobson in "Adaptive Antenna Array", patent No. PCT/AU85/00157, February 1986, which discriminates between useful signals and jammers by time, manages to reject interferences efficiently but does not seek to optimize the useful signal/noise ratio.
In a context of transmission, and when learning sequences are introduced into the waveform, it is preferable to use techniques of antenna processing with discrimination by modulation as they optimize the useful signal/noise ratio thus preventing the implementation of a goniometric step. However, most of the techniques employed today use complex weights on each of the sensors of the adaptive antenna. An antenna of this kind enables the rejection of the interferences, but in the presence of multiple paths of propagation:
it "aims" in the direction of one of the paths, i.e. it rephases the contributions of this path with the different sensors (for omnidirectional sensors, therefore, a gain in signal-to-noise ratio of 10 log N is obtained, where N is the number of sensors used),
and seeks to reject the paths decorrelated from this one, thus losing the energy associated with these paths.
In order to improve the performance characteristics of the last-named antenna processing technique, the idea is to couple it to a monosensor equalization technique. Multiple-antenna equalizers are thus obtained comprising a spatial part consisting of different filters positioned on each of the reception antennas and a temporal part positioned at output of the spatial part.
Receivers that carry out the joint processing of signals coming from several antennas have already been proposed to combat the selecting "fading" generated by the multiple paths in an unjammed environment. These are spatial diversity equalizers. As in monosensor equalization, the most commonly used solutions comprise either a Viterbi algorithm or a DFE structure minimizing the root mean square error (RMS error) between an obtained output and a desired output.
Spatial diversity equalizers based on a Viterbi algorithm are proposed especially in:
an article by P. Balaban and J. Salz entitled "Optimum Diversity Combining and Equalization in Digital Data Transmission with Applications to Cellular Mobile Radio--Part I: Theoretical Considerations", IEEE Trans. on Com., Vol. 40, No. 5, pp. 885-894, May 1992,
a patent by G. P. Labedz et al. (Motorola Inc., Schaumburg, Ill., USA) entitled "Method and Apparatus for Diversity Reception of Time-Dispersed Signals", patent No. EP 430481.A2, 12.12.1991,
a patent by Okanoue and Kazuhiro (NEC Corp., Tokyo, Japan) entitled "Noise-Immune Space Diversity Receiver", patent No. EP 449327.A2, Mar. 29, 1991, and
an article by P. Jung, M. Naβhan and Y. Ma entitled "Comparison of Optimum Detectors for Coherent Receiver Antenna Diversity in GSM Type Mobile Radio Systems", Proc. of the 4th International Symposium on Personal, Indoor and Mobile Radio Communications, PIRMC'93, Yokohama, Japan, 1993.
Their implementation requires prior knowledge of the pulse response of the transmission channel. When there is no jamming, the pulse response of the channel is estimated on the basis of the known symbols and the symbols decided as and when needed by the equalizer.
DFE structure spatial diversity equalizers are proposed in the article by P. Balaban and J. Salz and in an article by K. E. Scott and S. T. Nichols entitled "Antenna Diversity with Multichannel Adaptive Equalization in Digital Radio", Proc. of International Conf. on Com., ICC'91, New York, N.Y., USA, June 1991.
The last-named equalizer is made with self-adaptive filters whose coefficients are adapted by a least error squares algorithm. For the equalizer presented by P. Balaban and J. Salz, the coefficients are computed on the basis of an estimation of the transmission channel. The problem of the jammed environment is no longer dealt with in the study of these equalizers.
The spatial diversity equalizers referred to have been designed to combat the selective "fading" engendered by the multiple paths of the transmission channel, but not at all to reject interferences. However, of these equalizers, only the self-adaptive spatial diversity equalizer proposed by K. Scott and S. Nichols has the capacity to fulfil this last-named function. There is then obtained the transversal and recursive antenna which was the object of a doctoral thesis by L. Fety entitled "Methodes de traitement d'antenne adaptees aux radiocommunications" (Antenna Processing Methods Adapted to Radiocommunications), at the ENST, June 1988.
However, this processing can be applied only to transmission channels for which the time dispersal of the multiple paths in relation to the symbol duration is reduced, which is generally not the case in HF transmissions at high bit rates and in the GSM system. Indeed, in this context, the number of coefficients to be adapted is far too great for the adaptation algorithm to be capable of converging on a known learning sequence. The other spatial diversity equalizers presented depend on the estimation of the transmission channel which can hardly be obtained in the presence of interference. Furthermore, these equalizers do not integrate the interference rejection function.
In order to overcome the above-mentioned drawbacks, the present Applicant has filed a French patent published under No. 2 716 761 entitled "Procede permettant une egalisation multivoie dans un recepteur radioelectrique, en presence d'interferences et de multitrajets de propagation" (Method enabling a multiple antenna equalization in a radioelectrical receiver in the presence of interferences and multiple paths of propagation). This method provides jointly for a multiple-sensor equalization processing of the useful signal and a jammer rejection processing. It has the advantage of being an optimal method in the presence of temporally white noise (background noise+jammers), whatever the nature of the useful propagation channel. However, it leads to computation power that may have to be reduced in certain applications.
To this end, a French patent application entitled "Procede d'egalisation multicapteur permettant une reception multicapteur en presence d'interferences et de multitrajets de propagation, et recepteur pour sa mise en oeuvre" (Multiple-sensor equalization method enabling multiple-sensor reception in the presence of interferences and multiple paths of propagation, and receiver for its implementation) under number 95 14914, was filed on Dec. 15, 1995 by the present Applicant. It relates to a multiple sensor equalizer possessing computation power that is lower than the computation power of the multiple sensor receiver described in the above-mentioned patent application but can lead to lower efficiency performance when the useful propagation channel comprises several paths, owing to the fact that the multiple-sensor receiver is not the optimum in the presence of temporally white noise.
SUMMARY OF THE INVENTION
The invention is aimed at improving the performance characteristics of the prior receiver (patent 95 14914) by making improvements in the receiver according to the patent 2 716 761 while at the same time reducing the computation power of this receiver.
To this end, an object of the invention is a method enabling a multiple sensor equalization in a radioelectrical receiver comprising a specified number of reception antennas, said method comprising the steps of:
estimating the transmission channel on each of the antennas,
estimating the background noise component plus interference on each of the antennas on the basis of the estimation of the transmission channel,
estimating the spatial correlation matrix, referenced R b , of the background noise component plus interferences from the received signal,
computing a spatial-temporal filter formed for each discrete temporal element of the estimated multiple-sensor channel of a spatial filter,
achieving a temporal filtering of the data elements on the different sensors by the spatial-temporal filter, and
equalizing the signal at output of the spatial-temporal filter by one-dimensional equalization at a symbol rate deciding the symbols transmitted.
An object of the invention is also a receiver implementing the above-mentioned method.
The method according to the invention has the advantage of enabling an implementation of a novel multiple-sensor equalizer with lower computation power than the above-mentioned equalizers while at the same time being optimal when the noise is temporally white and enabling an efficient rejection of the jammers.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and advantages of the invention shall appear from the following description, made with reference to the appended drawings of which:
FIG. 1 shows the format of a GSM burst,
FIG. 2 is a simplified drawing of an optimum multiple-sensor receiver,
FIG. 3 shows the different steps of the method according to the invention,
FIG. 4 shows an exemplary embodiment of a receiver for the implementation of the method according to the invention.
DESCRIPTION OF THE INVENTION
The method according to the invention is based on a channel estimation performed on each of the input antennas of a multiple channel receiver that enables the computation of the coefficients of a spatial-temporal filter acting on the input data. The output of this filter is processed by a one-dimensional equalizer at the symbol rate which decides on the symbols transmitted. This equalizer may in particular be an equalizer based on the Viterbi algorithm or a DFE type equalizer.
The method jointly fulfils the following functions, namely a jammer rejection function, a function of optimization of the gain in the direction of the different useful paths, with a resetting of these paths in phase and a function of reduction of the distortions caused by the multiple paths associated with the useful signal.
The first two functions are fulfilled by the spatial-temporal filter, and the third function is fulfilled by the equalizer placed at output of this filter.
For example, the modulation used may be a GMSK type continuous phase modulation with an index 1/2 and a coefficient BT=0.3 with a symbol period equal to 48/13 μs. The symbols transmitted may be constituted, as shown in FIG. 1, by bursts of 148 symbols, sub-divided into two sequences of 3 filler bits at each end, a learning sequence consisting of 26 known bits placed in the middle of the frame and two sequences of 58 information bits.
The data elements d n representing the sequence (d n ) of the bits to be transmitted are encoded differentially before being modulated. The information transmitted consists of a sequence (a n ) computed from the sequence (d n ) by the following formulae.
a.sub.n =1 if d.sub.n =d.sub.n-1 and a.sub.n =-1 if d.sub.n ≠d.sub.n-1(1)
The GMSK modulation used is of the type described in the article by P. A. Laurent, "Exact and approximate construction of digital phase modulation by superposition by amplitude modulated pulses (AMP)", in IEEE Trans. Comm., Vol. 34 (1986), pp. 150-160.
This modulation is expressed approximately in the form of a linear modulation defined by the relationship: ##EQU1## where C 0 (t) is the primary main function of the GMSK modulation.
In this case, the modulated signal z(t) can also be put in the form of a convolution product such that: ##EQU2## taking s n =j n b n
The sequence (s n ) constitutes the sequence of the symbols transmitted. The demodulation consists in determining the sequence (s n ) and then making a trace-back to the sequence of bits transmitted (d n ).
The transmitted signal z(t) reaches a reception array comprising K sensors after it has passed into the mobile radio propagation channel.
The multiple-sensor signal received is expressed as follows on the basis of the signal s(t):
X(t)=[x.sub.1 (t), . . . , x.sub.K (t)].sup.T =s(t)*G(t)+B(t),
where:
G(t) is the multiple-sensor channel received, constituted by the total waveform of emission C 0 (t), the emission filter, the propagation channel and the reception filter,
x i (t) is the signal received by the sensor i.
X(t) may also be written as a function of the symbols transmitted: ##EQU3## where Ts is the symbol period.
The article by P. Vila, F. Pipon, D. Pirez and L. Fety, "MLSE Antenna Diversity Equalization of a Jammed Frequency-Selective Fading Channel", Proc. EUSIPCO'94, pp. 1516-1519, Edinburgh, UK, September 1994 has presented the optimum multiple-sensor receiver as understood in terms of minimization of probability of decision error on the transmitted sequence. This optimum receiver, as shown in FIG. 2, implements a spatial-temporal adapted filter hereinafter designated by the abbreviation "STAF", whose expression is given by the relationship:
W(t)=R.sub.b.sup.-1 (t)*G(t), (5)
where R b (t) is the correlation function of noise B(t). It also implements a sampler T at the symbol rate and a decision unit OD that determines the sequence of symbols transmitted. The decision element is based on the Viterbi algorithm as described in the article by J. G. Proakis, "Adaptive equalization for TDMA digital mobile radio", IEEE Trans. on Vehicular Techn., Vol. 40, No. 2, May 1991. This algorithm makes it possible, on the basis of the sequence (y n ) obtained at output of the STAF filter, to find the sequence (s k0 n ) with an index k 0 that minimizes the probability of decision error in the sequence of symbols transmitted or again, in an equivalent manner, that maximizes the following criterion: ##EQU4##
The Viterbi algorithm works on the basis of the output signal from the STAF filter y n and the coefficients γ n .
The implementation of the above processing operation in multiple-sensor receivers makes it possible to obtain optimum reception as understood by the minimization of the probability of decision error in the sequence of symbols transmitted in the presence of background noise and jammers.
The multiple-sensor receiver of the invention constitutes an implementation of the optimal multiple-sensor receiver presented here above in the special case where the noise is temporally white (R b (t)=R b ). It is therefore the optimum when the jammer is temporally white (which is approximately the case in the GSM system where the modulation of the jammers is the GMSK modulation) and when it comprises a single propagation path, regardless of the nature of the useful channel.
According to the invention, the matrix R b is estimated by means of a channel estimation algorithm performed on each of the input antennas. The different processing steps to be implemented are shown in the flow chart of FIG. 3.
The first step, which is represented by the reference 1 in FIG. 3, consists of the performance of an operation to digitize the signals applied to the sensors, transpose them in baseband and then filter them by a reception filter. A complex signal sampled at a frequency Fe which is a multiple of the symbol frequency Fs (Fe=2 Fs for the exemplary embodiment) is obtained at the end of the step 1.
The step 2 performs the synchronization of the receiver with the symbols received. This step can be performed as described in the patent application filed by the present Applicant on Jan. 21, 1994 entitled "Synchronisation en presence de brouilleurs et de multitrajets" (Synchronization in the presence of jammers and multiple paths), corresponding to U.S. Pat. No. 5,812,090.
It enables the receiver to be positioned in such a way that the received signal X(n Te) is expressed as a function of the signal transmitted s(n Te), s[(n-1) Te], . . . , s[(n-L+1) Te], where L represents the length (in number of samples) of the useful propagation channel taken into account during the demodulation following the relationship: ##EQU5##
For example, by choosing L=12 (with F 2 =2F s ), the number of states taken into account in the Viterbi algorithm is equal to 2.sup.(L/2)-1 =32.
Under these conditions, the samples of the signal s(n Te) are expressed on the basis of the symbols transmitted by the relationship:
s[(2n)Te]=s.sub.n et s[(2n+1)Te]=0.
The step 3 is aimed at performing n spatial-temporal filtering operations when the noise is temporally white. It requires the estimation of the useful channel G(t) and of the correlation matrix of the noise R b . This estimation is achieved at the step 4 by performing the following estimations:
A first estimation consists in estimating the transmission channel on each of the input antennas:
By using the expression G k to designate the vector constituted by means of the temporal samples of the propagation channel on the antenna k:
G.sub.k =(g.sub.k (0), . . . , g.sub.k [(L-1)Te]).sup.T (8)
where g k (t) represents the channel obtained on the antenna k and taking:
S(nTe)={s(nTe), . . . , s[(n-L+1)Te]}.sup.T
to denote the vector formed by means of the known symbols of the learning sequence, the signal received by the antenna k is written as follows:
x.sub.k (nTe)=G.sub.k.sup.H S(nTe)+b.sub.k (nTe) (9)
and the estimation of the channel on the antenna k is obtained by the known Wiener formula:
G.sub.k =R.sub.SS.sup.-1 r.sub.sx (10)
In the context of the GSM application given as an example, the correlation matrix R SS and the intercorrelation r sx may be estimated on the 16 bits placed at the center of the learning sequence (namely on N=32 samples) by the non-biased standard estimator: ##EQU6## where the operator " H " represents the operation of transposition-conjugation.
The learning sequences of the GSM system are chosen so as to obtain a cancellation of the self-correlation function on five symbols on either side of the instant t=0. In this case, the matrix R SS is equal to the identity matrix and therefore the channel estimation is obtained directly from the knowledge of the intercorrelation vector rS x , whence we get G k =r Sx .
A second estimation consists in estimating noise samples on each of the input antennas.
On the basis of the estimation of the propagation channel, it is indeed possible to obtain an estimation of the noise samples on each of the input antennas by the formula:
b.sub.k (nTe)=x.sub.k (nTe)-G.sub.k.sup.H S(nTe) (12)
This makes it possible to obtain an estimate of the noise vector B(nTe)=[b 1 (nTe), . . . , b K (nTe)] T for the N samples used by the channel estimation.
A third estimation consists in estimating the correlation matrix of the noise R b :
The correlation matrix of the noise is obtained from the noise samples B(nTe) estimated by the non-biased standard estimator. It is obtained by the relationship: ##EQU7##
The computation of the coefficients of the spatial-temporal filters obtained at the step 3 by the relationship:
[W(0), W(Te), . . . , W(L-1)Te]=R.sub.b.sup.-1 |G(0), G(Te), . . . , G(L-1)Te| (14)
The coefficients of the filter are obtained either by resolving all the linear systems contained in the equation (14) or by reversing the matrix R b by any appropriate method for the inversion of hermitian matrices and especially the Gauss pivot method.
If the length of the channel is smaller than the number of sensors (L≦K), it may be advantageous, in order to reduce the computation power, to refrain from computing R b -1 , but to directly resolve the six linear systems (for example by the method of the Gauss pivot):
R.sub.b W(iTe)=G(iTe).
The step 5 consists in computing the coefficients used by the Viterbi equalizer:
The coefficients γ n used by the Viterbi algorithm are obtained by the formula (6). These coefficients are expressed also as a function of the vectors G(iTe) and W(iTe) according to the relationship: ##EQU8##
These coefficients represent the inter-symbol interference model at output of the spatial-temporal filter which has to be processed by the one-dimensional equalizer.
(The factor 2n is due to the fact that the coefficients used by the Viterbi algorithm are computed at the symbol rhythm.)
The spatial-temporal filtering of the input signals is obtained at the symbol rhythm from the estimated filters during the previous step: ##EQU9##
One embodiment of a receiver for the implementation of the method according to the invention is shown in FIG. 4. This embodiment has a first block 6 for the digitization of the signal applied to each of the K reception antennas. A second one-dimensional equalization block is coupled to the first block 6 by means of a third spatial-temporal filtering block 8. A fourth block 9 computes the coefficients of the spatial-temporal filter block 8 as well as those characterizing the useful channel at the input of the one-dimensional equalization block 7. Finally, a fifth block 10 synchronizes signals between the different blocks.
In a first embodiment of a receiver according to the invention, the equalization block may be programmed to retrieve the symbols transmitted by minimizing the probability of decision error according to the Viterbi algorithm. In this case, the coefficients γ n to be taken into account to perform the Viterbi algorithm are those defined by the relationship (15).
This embodiment however is not unique and other types of algorithms such as the above-mentioned "M algorithm" which is a simplified version of the Viterbi algorithm or again a DFE type equalization may also be implemented to obtain the equalization block 7. However, the results obtained by these embodiments then appear to be slightly deteriorated when compared with those that can be given by an equalization implementing the Viterbi algorithm. They may however be used in applications where the available computation power is insufficient for the performance of the Viterbi algorithm.
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A method enabling a multiple sensor equalization in a radioelectrical receiver including a specified number of reception antennas, the method including the steps of estimating the transmission channel on each of the antennas; estimating the background noise component plus interference on each of the antennas on the basis of the estimation of the transmission channel; estimating the spatial correlation matrix referenced R b of the background noise component plus interferences from the received signal; computing a spatial-temporal filter formed for each discrete temporal element of the estimated multiple-sensor channel of a spatial filter; achieving a temporal filtering of the data elements on the different sensors by the spatial-temporal filter; and equalizing the signal at output of the spatial-temporal filter by one-dimensional equalization at a symbol rate deciding the symbols transmitted.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority of Provisional application Ser. No. 60/804,024, filed on Jun. 6, 2006, the disclosure of which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] This invention relates to a device and method that inhibit decubitus ulcers.
BACKGROUND OF THE INVENTION
[0003] Decubitus ulcers (DU) are produced by point pressure over bony prominences. As skin ages, it loses its underlying fat layer which usually distributes pressure over a wider area. The skin itself also loses fat. The diameter of the bony prominence, the weight of the patient, and the duration of the pressure are important factors in the production of DU. When the interdermal pressure exceeds the capillary filling pressure, the skin becomes ischemic and dies. See the diagram of FIG. 1 , which explains the formation of DU 10 . DU's are cold thermo-graphically, which is why they are slow to heal. This dead skin slowly liquefies and becomes an ideal growth medium for bacteria. Open, oozing, foul-smelling, grey lesions are the result. DU's are time-consuming to prevent and treat and are the leading cause of death in rest homes and long term care centers.
[0004] There is a well-described animal correlate available. Falconers for centuries have described a lesion on the distal end of the tarso-metatarsus [palm] of the foot the call Bumble-foot. This scab-like lesion can be removed and its under-side is a white caseus material. Birds have little fat in their skin and they lack liquefying enzymes in their white blood cells. Long term perching on hawk perches produces an ischemic ulcer called Bumble-foot. The patho-physiology is the same as DU's Current DU treatment devices compress under the weight of the patient, forming smooth large contact areas, which accounts for their failure in preventing DU's. Sheep's wool, inflatable beds, foam pads, egg-crate pads and the like all fail to prevent skin ischemia. See FIG. 2 for a diagram that shows how a “pressure dressing” 12 , such as those described just above, simply enlarges the weight-distribution area, which does not alleviate the problem, thus still allowing the formation of DU 10 a . Failure of these products is evident in the anatomy of the skin lesions. The skin dies at a central point and there are concentric rings of dying skin from the central point outward. The rings indicate the decreasing pressure from the center outward to viable skin. Inflatable knobs and foam knobs compress to form a large diameter constant pressure point and the bed-sheets make it worse.
[0005] DU's remain a major cost of care and a significant mortality factor. There is a pressing need for an effective means to help prevent the formation of DU's, and help in their treatment.
SUMMARY OF THE INVENTION
[0006] For skin to remain viable the pressure of contact must be less than the capillary filling pressure of a given area of skin. The contact area must be small enough to allow perfusion of tissue around the compressed area. By supporting the weight on sharp points and edges there is sufficient perfusion to allow nutrition of tissue between the points.
[0007] Prevention/treatment of DU's involves changing the biophysics of the DU production process. The weight of the patient must be distributed over a wider area, and the skin needs to be supported on points and not on smooth surfaces. Point support allows for the nutritive capillary flow between the points so the skin does not become ischemic.
[0008] This invention features a method and device to promote the healing, or prevent the breakdown, of skin that may be subject to breakdown from body weight pressure, comprising supporting the skin and underlying tissue on multiple small points and/or edges of a support pad that defines a number of resilient bristles or blades. The support pad may include an adhesive material that removably attaches the pad to the skin. The pad may be made of plastic material. The bristles or blades may be shaped so that the multiple small points and/or edges of tissue contact are provided by the end-points of the sides of straight or curvilinear bristles or blades projecting from a base. The projections may be arranged in a manner that provides multiple skin contact points per square inch. The multiple small points of tissue contact may be arranged to support the tissue off the base of the pad while allowing blood circulation to the tissue between and proximate to the multiple points of skin contact. The blood circulation to the tissue is sufficient to support the maintenance or re-establishment of skin.
[0009] The pad may be disposable. The pad may be packaged to meet standards of medical sterility. The pad may be non-disposable. There may further be included a material cleaning system that adequately prevents the non-disposable material from becoming a source of tissue infection. The material cleaning system may utilize an anti-microbial cleaning solution, or may utilize a high-pressure washing system.
[0010] The pad may be silver-impregnated. The adhesive may be air-porous and impervious to liquids and bacteria. The adhesive may be in contact with the pad bristles. The pad may have a backing and the adhesive may be in contact with the backing. The pad may have a backing that is occlusive, or that is perforated or that is constructed to be non-skid, to help maintain the pad in place. The bristles or blades may be long enough to create a space between the skin and the pad backing to collect body fluid away from the skin. The bristles or blades may be of different lengths and/or different stiffness and curvature to allow for varying levels of body weight support in order to accommodate varying body weights and size of patient pressure points, and varying levels of comfort in sensient patients.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Other objects, features and advantages will occur to those skilled in the art from the following detailed description of the invention, and the accompanying drawings, in which:
[0012] FIG. 1 is a schematic cross-sectional view of a decubitus ulcer over a bony prominence in a patient;
[0013] FIG. 2 is a schematic cross-sectional view of a decubitus ulcer over a bony prominence in a patient, with the use of a prior art pressure dressing;
[0014] FIG. 3 is a schematic cross-sectional view showing an embodiment of the method and construction of this invention for treating a DU, in which the skin over the bony prominence is supported in a manner that re-establishes blood flow and supports the growth of capillaries overlying the prominence;
[0015] FIG. 4 is a schematic cross-sectional view of the location shown in FIG. 3 as the DU continues to heal; and
[0016] FIG. 5 is a schematic cross-sectional view showing another embodiment of the method and construction of this invention, for preventing the formation of DU's over a bony prominence, in which the skin over the prominence is supported in a manner that allows for capillary blood flow and thus supports the maintenance of healthy tissue overlying the prominence.
DETAILED DESCRIPTION OF THE INVENTION
[0017] The invention is accomplished by providing a pad 20 , FIGS. 3-5 , that is located at patient pressure points, such as the seat, elbows, heels and back; the particular areas depending on the patient and the manner in which the patient is supported, such as in a bed or a wheelchair, for example. Pad 20 defines a multi-point surface defined by structures (typically bristles or blades that have some resiliency) 24 having points/edges 22 , similar to a brush. Pad 20 maintains skin capillary flow. Bristles or blades 24 of pad 20 need to be resilient enough to support the patient's weight over the particular contact area, and long enough to allow for some sinking-in (bending of bristles/blades 24 ) without reaching the backing 26 . In other words, the bristles/blades must present a contact area that is small enough to allow perfusion of tissue 26 around the compressed area, to support reestablishment of tissue 30 , FIG. 4 , in place of DU 10 . By supporting the weight on sharp points and edges there is sufficient perfusion to allow nutritive capillary flow between the points so the skin does not become ischemic.
[0018] The product “Astroturf”™ from Solutia, Inc. has been determined by the inventor herein to meet these criteria. Astroturf was first described in U.S. Pat. No. 3,332,828. Astroturf is made from polyethylene in the form of eight, one-sixteenth by three-quarter inch kinked bristles/blades in a tuft. The tufts are arranged in parallel rows to form a bristle-like surface. There are about 40 bristles/blades per square inch.
[0019] Other brush-like surfaces could be used to fit specific needs. The size, length, thickness and packing density of the bristles/blades, and the material from which they are made, can be designed to achieve a certain weight support per area. For example, heel cups to support heel pressure while a person is seated or lying down can be relatively soft, while coccyx pads used while a person is seated in a wheelchair need to be larger and stiffer in order to support the torso weight without collapsing and losing their effectiveness. Anti-bacterial and/or wound-healing materials such as silver could be added to the bristles/blades. This could help to minimize skin and/or ulcer infection, or inhibit bacterial growth in wound exudate that collects in the pad. Different bristle/blade densities and resilience could be made for different compressive requirements.
[0020] The invention contemplates single use pads or the re-use of pads through cleaning such as with anti-microbial cleaning solution and/or a high-pressure washing system or sterilization by known means. The pads and/or the bristles or blades can be made of any material having the desired properties, such as rigid or semi-rigid material made of metal or plastic (e.g. polyethylene or Nylon) or wood or paper or other similar organic or non-organic material. The pad material can be designed to be easily cut to the desired size and shape pad.
[0021] The bristle/blade material is shaped so that the multiple small points and/or edges of tissue contact are provided by the end-points and by the sides of straight or curvilinear projections from a base. The projections are arranged in a manner that provides multiple skin contact points/edges per square inch. The multiple small points/edges of tissue contact are arranged to support the tissue off the base of the pad while allowing blood circulation to the tissue between and proximate to the multiple points of skin contact. The blood circulation to the tissue is sufficient to support the maintenance or re-establishment of skin. It is believed that a body pressure of less than about 30 mm Hg is necessary in order to support capillaries and therefore skin. The bristles/blades could be made long enough to create a space between the skin and the pad backing to collect fluid away from the skin. The bristles/blades could be of different lengths and/or different stiffness and curvature to allow for varying levels of body weight support in order to accommodate varying body weights and size of patient pressure points, and varying levels of comfort in sensient patients.
[0022] Back side 26 or the skin side 27 of pad 20 could be covered with a fluid-occlusive dressing such as Tegaderm, a 3M product that is a clear film dressing material that is adhesive, air-porous and impervious to liquids and bacteria. On front or skin side 27 , this would help to keep the pad in place on the skin while keeping wound fluid in and urine, feces and other contaminants out. On back side 26 (or by designing the back side to be impervious), the dressing material can help to trap body fluid. Any such covering could be made larger than the pad to achieve skin adhesion and fluid control. Alternatively, the pad backing 26 could be perforated to allow drainage through the pad, and/or be designed to be non-skid so that it stays in place on a bed or wheelchair more easily. As yet another alternative, the pad could be attached to an adhesive material larger than the pad to keep the pad in place on the skin.
[0023] Advantages/uses of the invention:
Support patient's weight on points/edges through wide range of weights. Point/edge support allows for maintaining tissue perfusion. Bristles/blades are resilient enough to resist compression. Bristles/blades allow for air circulation next to the skin keeping it dry. Urine drains away from the skin. Can be used for both prevention and treatment of DU's. Can be used to relieve risk of long term sitting in cars, on bleachers, boats and kayaks, at office desks, etc. Can decrease the likelihood of ulcers in high-risk patients such as diabetics, spinal-cord injuries or dementia.
[0031] Although specific features of the invention are shown in some drawings and not others, this is for convenience only as the features may be combined in accordance with the invention. Other embodiments will occur to those skilled in the art and are within the following claims.
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A method and device to promote the healing, or prevent the breakdown, of skin that may be subject to breakdown from body weight pressure. A support pad that defines a number of bristles or blades is placed so as to support the skin and underlying tissue on the multiple small points and/or edges of the pad bristles or blades.
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BACKGROUND OF THE INVENTION
The present invention relates generally to agricultural machinery such as harvesting machines and, more particularly to such a machine including a conveying device having conveying rollers with a metal foreign body detection device mounted in front of a chopper mechanism. The detection device controls rapid stopping of the conveying rollers whenever a foreign body is detected in a foreign body detection region of the conveying device, before the foreign body reaches the chopper mechanism.
A device of this kind is known from German Patent 4 129 113 A1. Whenever the conveying rollers are stopped because of detection of a foreign body, it is necessary to remove the foreign body from the conveying region so that the chopper mechanism is not encumbered by it. In some cases the foreign body leaves the conveying zone without further action through a gap between two conveying rollers arranged one behind the other. Often, however, the conveying direction must be reversed so that the foreign body can be removed from in front of the first conveying rollers or so that the foreign body is caused to drop out. Sometimes during reversed conveying the foreign body is picked up and entrained by the upper ribbed conveying roller, which generally is a pressure roller. Upon return to forward rotation the foreign body drops into the conveying path, that is, directly in front of the chopper and into the chopper mechanism. Also the foreign body frequently can be found only after long searching because the region of detection of the detection device is spatially extensive. Moreover, the rapid stop leaves a different path of conveying, depending upon the speed of conveying at the moment of switching. This makes it even more difficult to locate the foreign body. The sensitivity and filter properties of the detection device are influenced as a function of conveying speed signals and the gap width between the pressure roller and conveying drive roller. Thus, foreign bodies are detected from a critical size onward.
Also it is known from German Patent 4 301 611 A1 that several magnetic pole regions and detector coils can be arranged in the direction of conveying and transversely to the direction of conveying. As a result, various wanted signals are picked up in different regions of the path of conveying and hence extensive compensation of interference signals, which arise due to magnetic field-active structures, particularly transverse ribs, on the conveying rollers occurs.
It is an object of the invention to overcome one or more of the deficiencies described above.
It is another object to facilitate the removal of detected foreign bodies from the conveyor of an agricultural machine; and/or to improve the location for such removal.
SUMMARY OF THE INVENTION
In accordance with the present invention there is provided an agricultural machine having conveying rollers; a chopper mechanism; a foreign body metal detection device mounted in front of the chopper mechanism for detecting unwanted foreign bodies in a foreign body detection region; means associated with the detection device for rapid stopping of the conveying rollers before a foreign body reaches the chopper mechanism; and means operative after a rapid stop of the conveying rollers, for reversing the same in a controlled manner so that backward conveying takes place until the foreign body has again passed through the foreign body detection region.
In accordance with another feature there is provided a method of operating a conveying device on a harvesting machine having conveying rollers and a chopper mechanism, including the steps of: detecting whenever a foreign body enters a detection region adjacent the conveying rollers; stopping the conveying rollers before the foreign body reaches the chopper mechanism; and after stopping, reversing the conveying rollers until the foreign body has passed back through the detection region.
After rapid stopping, the backward conveying takes place in a controlled fashion until the foreign body has again passed through or left the foreign body detection region.
The invention makes use of the existing measuring and locating means to control backward conveying in such a way that foreign objects to be removed are readily accessible in a narrowly limited region in front of the conveying rollers. Backward conveying is advantageously carried out until an upper conveying roller has entrained the foreign body to the highest circumferential point thereof.
Using the measurement of revolution of the upper conveying roller limits the range of backward rotation. In certain circumstances, this prevents metal foreign bodies picked up in the supply region from being deposited by the conveying chopper in front of the chopper mechanism, which would cause damage upon the advancing again.
Advantageously it is provided that after the control device reverses the conveying process, the operator is offered an indication of whether the foreign body was detected again during backward conveying. If the foreign body is not detected, the foreign body has usually left the conveying zone through a gap in the conveying channel and a search is unnecessary.
The metal foreign bodies which may damage the chopper mechanism and which must not get into the feedstuffs can be a variety of different objects such as bolts, bars, chains, wires and bushes or sheet metal parts which can lie longitudinally, transversely or in any other direction and at any level relative to the conveying zone. Therefore, these different foreign bodies may remain for a longer or shorter distance and time in the detector region and also may cause differing characteristic detector signals. Since the length of the braking distance of the rapid stop brake varies, depending upon its adjustment and state as well as on the respective speed of conveying and quantity, the detected metal foreign object may or may not have already left the detector region when braking is over. Therefore, it is advantageous if, when tracing the foreign body, there is distance measurement with the angle transmitter signals of a conveying roller, which are used in detail for detector control, from the moment of first detection thereof until stopping. Furthermore, it is advantageous to measure the length of the object by means of the transmitter signals, which occur during the detector signal.
These measurements make it possible to monitor the position during return because within the scope of the tolerances, which occur due to a change of position in the stream of feedstuffs, and the differences in response thresholds of the detector with the decreasing or increasing speed of the conveying device, it can be assumed that a measurement of extent and position during return shows similar results. Therefore, during backward transport the angle transmitter signals of the conveying roller are evaluated and a tolerance comparison is made with the previously measured and stored admissible values. In case of substantial deviations from the expected measurement results, such deviations are reported to the operator, just as the extent of the object is signaled to the operator. This information serves as an important aid in locating and identifying the unwanted object. Even if the object is no longer detected during reversal, this fact is reported to the operator.
In addition or as an alternative to the position information provided by the angle transmitter signals, position information is also contained in the detector signal or detector signals where several induction detector coils are arranged on the magnets. The signals in each case consist of a positive and a negative part wave, which arise when the object enters and leaves the magnetic field, in different regions of the conveying channel. In the event that the magnet assembly includes a T-shaped yoke, whose yoke arms extend in the direction of conveying, signal rise and signal decay occur in two different regions of the conveying zone. If separate coils are arranged on the arms, then the signals occur there separately and are to be spatially allocated. Thus, the entry and exit of the object can be detected by zones by evaluating the signals and their direction of rise. The time ratio of the signals and their differentials indicate the length of the object. It should be noted that in certain circumstances the speed of the material being conveyed is not constant due to braking or starting. Correlating the different signal components to the angle transmitter signals is therefore helpful to achieve even greater accuracy.
Two different ways are provided for detecting the object according to position and size, upon entry and during backward transport. As a result, there is increased safety due to the fact that the backward motion is ended at almost the exact same time that the object is positioned at the entrance to the conveying rollers and has left them completely. Moreover the angle transmitter pulses are also used to fix the limit for backward transport, so that the foreign body, if it has been picked up by the upper roller, is not conveyed over the upper roller.
A further improvement in the device is yielded by separate evaluation of the sensor signals, divided into several sensor segments across the width of the conveyor, which is customary to reduce interference. Using a new type of circuitry, the signals of the individual coils, which are generated essentially synchronously by the interfering rotating and/or vibrating machine parts, are advantageously averaged and in each case subtracted from the individual coil signals, so that only the foreign body interference in sections is emphasized as difference signals, thereby indicating the position of the foreign body. These individual difference signals are processed and compared with a threshold value and indicated to the operator after they occur, allowing the operator to search for the interfering object within a much narrower space.
The necessary signal links and processing can be done by circuitry or, after digitalization of the signals, by software. The known inversely speed-dependent signal gain or speed-dependent signal attenuation before digitalization is preferably used to achieve a good signal/noise ratio.
A further development of the device is that the magnet sensor assembly, which is usually accommodated in the conveying roller, is mounted pivotally about an axis parallel to the roller axis or about the roller axis itself and connected to a pivot drive.
As a result, the position finding region can be displaced in a direction toward the chopper and any objects which may be located between the conveying roller and a subsequent roller can be detected at any given time during pivoting itself or during the subsequent reversing movement of the conveying device. However, this must be performed in a sufficiently rapid manner to obtain a usable signal during pivoting.
Backward transport of the object and its end position are verified exactly and accordingly indicated to the operator by means of backward pivoting of the detector device to the entrance. The pivot movement can also be performed dynamically through a preset angle of adjustment, so that a detector signal is generated continuously when there are metal parts in the fluctuating field region.
Also by pivoting the detector device into a position symmetrical to the interfering rotating components of the conveying device, minimization of the interference level can be achieved, as the signals have opposite poles during entry and exit of the conveying ribs and they are periodic due to the ribs distributed evenly over the circumference.
Instead of the known magnetic/electrodynamic sensors under consideration here, detectors with static magnetic field sensors can also be used. These sensors have the advantage of taking up speed-independent magnetic field variations due to unwanted ferromagnetic objects, even at a standstill. However, other metal objects can also be verified with these sensors only dynamically. A combination of electrodynamic and magnetostatic sensors can be used advantageously according to the invention by evaluating the signals during backward conveying.
A further advantageous use of the device produces checking of the rapid cutout coupling for its switching behavior, so that the redundancy in the path of conveying from triggering of rapid stopping until stopping of conveying is so great that no foreign object will invade the chopper mechanism. For this purpose, while the conveyer is running, rapid triggering is repeatedly triggered with a key signal and in each case the distance of conveying is determined by counting the rotary transmitter pulses. The release latch of the stop coupling is electromagnetically operated and must cover a switching distance before it engages a locking tooth on a ring gear in order to be held fast. There is the risk of delayed locking if the latch movement is too slow or if wear of the locking teeth has progressed. Moreover there is a switching distance tolerance due to the distance between the locking teeth. Therefore several rapid cutout means are advantageously triggered and the respective conveying distance is determined by counting the rotary angle transmitter pulses. The highest count is used with a tolerance supplement as the threshold value for the subsequent checks of the rotary transmitter pulses, which have been reached at any given time in case of rapid cutouts. If the limit value is exceeded, an indication is given which determines whether maintenance and checking of the rapid switching device is necessary.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference is now made to the drawings which illustrate the best known mode for carrying out the invention and wherein:
FIG. 1 is a side view of a conveying and chopping mechanism with part of the cover removed for better illustration;
FIG. 2 is a cross-sectional view through a state of the art sensor device;
FIG. 3 is a cross-sectional view through another state of the art sensor device;
FIG. 4 is a top view of the FIG. 2 sensor device; and
FIG. 5 is a block diagram of a control device for use with the FIG. 1 mechanism.
DETAILED DESCRIPTION
FIG. 1 shows a detail of a harvesting apparatus whose stream of cut material is supplied via a conveying path B and subsequent pairs of conveying rollers 21-24 to a chopper mechanism 25. The lower conveying roller 21 is driven. The upper conveying roller 22 is vertically pressed by a contact pressure means A to the stream of material and hence against the lower conveying roller 21. The upper and lower conveying rollers 22, 21 are provided with transverse ribs. Downstream, an additional pair of smooth rollers 23, 24 is arranged, and behind them the cutter and the chopping roller 25, which is provided with blades.
A foreign body detection device 1, whose magnetic field beams NF1, NF2 pass through the roller casing and the conveying gap, is arranged in the lower conveying roller 21. An angle transmitter 3, whose angle sensor 31 signals are delivered to a control device in front of the sensor windings of the magnetic detection device, is arranged on the shaft of the conveying roller 21. If a metallic or electrically conductive or ferromagnetic foreign body passes through the magnetic fields NF1, NF2, electrical signals occur in the sensor winding, which are used for rapidly stopping the conveying device comprised of rollers 21-24. During this stop time, i.e. from the stop signal to stopping, the degree of rotation of the conveying roller 21 is determined by means of the angle sensor 31 signals, thereby establishing how far the foreign body has been further transported in a direction toward the chopper 25. Accordingly, the return movement is then controlled and simultaneously the foreign body is checked to determine whether it has left the sensor magnetic field NF1.
If the foreign body is not completely transported back, but leaves the conveying region through the gap SP1 between the lower conveying rollers 21, 23 in the braking time or during initial reversal, this is detected by the absence of sensor signals during reverse movement and signaled to the operator. In the absence of indication of passage of a foreign object during reverse movement of the conveying rollers 21, 23, the reverse movement is limited in such a way that on no account can the object be unknowingly entrained by the pressure roller 22. The degree of reverse rotation is continuously determined by means of the angle transmitter 3 and angle sensor 31, and upon reaching a predetermined limit angle G, reverse transport is stopped. Advantageously, the reverse movement of the upper conveying roller 22 can be even more accurately measured by an angle transmitter mounted thereon (not shown) which is like angle transmitter 3 and angle sensor 31.
An advantageous embodiment the foreign body sensor 1 is provided with a pivot or swing drive 50 (see FIG. 5) which allows the sensor to detect foreign bodies as far forward as possible during entry into the rollers 21, 22. Likewise, the pivot drive 50 allows the sensor 1 to detect foreign bodies as far rearwardly as possible on the chopper side after rearward pivoting. The sensor 1 may also detect foreign bodies in the rear gap SP1. Thus a foreign body can be detected in the whole conveying region in front of the chopper 25 and, after forward pivoting or repeated pivoting, detected or traced as far forward as the position of removal at the entrance to the conveying rollers 21, 22. The pivoting arrangement makes it possible to adjust the sensor beams NF1, NF2 (see FIG. 1 or 3) symmetrically to the passage of the interference-producing ribs of the conveying rollers 21, 22, so that the periodic unwanted signals generated thereby are largely compensated. This is the case particularly when the ribs of the conveying rollers 21, 22, which are located in the region of the magnetic sensor field beams NF1, NF2, are spaced apart such that the distances between them correspond to the spaces of the field edges and thus the successive entering and exiting ribs in each case generate oppositely polarized sensor signals. As shown in FIG. 1, the upper conveying roller 22 has a larger diameter than the lower roller 21 nearly to the extent that the field edges diverge at a distance from the roller surfaces.
FIG. 2 is a cross-section through an ordinary magnetic field sensor 1. A U-shaped soft iron yoke J encloses one pole S of the centrally mounted magnet M, so that the yoke arms diverge slightly laterally of the magnet M. The magnetic field beams NF1, NF2 exit, slightly diverging into the space in front, between the free pole of the magnet M and the laterally descending end faces PZ, PA of the yoke arms. A sensor coil S1 is wound around the magnet M so that field variations in the magnetic field due to moving electrically conductive objects induce a voltage therein which is delivered as a sensor voltage.
FIG. 3 shows another known embodiment of the magnetic sensor assembly 1 * in which sensor coils SZ, SA are mounted upon each of the two arms of the yoke J. In this way two separate sensor signals can be obtained, which in each case signal the entry and exit of a conductive object into and out of the associated magnetic field beams NF1, NF2 with corresponding polarity. As a result, the entry and exiting movement of an object can be tracked from the signal sequence of the two sensor signals. Furthermore, a ratio of the movement of the object in the direction of conveying to the distance between and lateral extent of the signal beams NF1, NF2 can be derived. For this purpose the occurrence of the entry and exit sensor signals in relation to their position is picked up to follow the angle sensor signals, taking into account the numbers of angle sensor signals which in each case correspond to the mean field beam width and the mean distance between field beams. Naturally a relative size and position of the object can also be determined based upon the time positions relative to each other, without a correlation to the angle sensor signals. However, there is greater inaccuracy when the speed of the object changes due to braking or acceleration of the stream of material during measurement.
FIG. 4 shows a top view of a sensor device. Several elongate magnets M1, M2 etc. are arranged transverse to the conveying path B and slightly spaced from each other in the common U-shaped yoke J. Each magnet M1, M2 has its own sensor winding S1, S2, and their poles N, S are arranged alternately. The field beams from the poles N, S to the yokes J are relatively narrow in the direction of the conveying path B, but elongate from the end pole faces N, S, emerging further according to the greater distance. The signals of the individual coils S1, S2 are advantageously used to compensate for unwanted signals of the moving machine parts occurring with opposite polarity, particularly ribs of the conveying rollers 21, 22. The signals of the individual coils S1, S2 are also individually tested for wanted signals, so that the position of a detected foreign body assigned to the individual sensor section, which substantially facilitates finding the object for removal. The number of magnets and coils is to be selected from practical viewpoints.
FIG. 5 shows a circuit with a control processor PC which detects the different sensor signals of the magnetic pick-ups S1, S2; SA, SZ after their initial signal processing. The control processor PC also detects angle transmitter signals of angle transmitter 3 and angle sensor 30 on the conveying rollers 21, 22 and further processes them. Signal preprocessing appropriately concerns controlled amplification or attenuation which makes the signal amplitude ratios largely independent of the rate of advance. The control signal VS for amplification control is derived from the angle transmitter signals.
The process signals of the signal transmitters S1, S2; SA, SZ are conveniently transmitted by a multiplexer MPX to an analogue-to-digital converter ADU and then the signals are further processed digitally. Further processing is used to determine the individual wanted signal components by formation of an interference compensation quantity from the individual signal values and possibly by an adapted filter according to the time sequence of the unwanted signals. The signal transmitters SA, SZ; S1, S2 in FIGS. 3 and 4 exist in a substantially larger number than shown, such number being a function of whether there are sensor coils located one behind the other and/or adjacent each other.
The signals of the different signal transmitter coils are, depending upon direction, compared with matching threshold values. If any of the thresholds is exceeded, the entry or exit of an object into or out of the associated field region is recorded. The first signal to occur serves to activate rapid cutout SS. The first signal also serves to activate commencement of further analysis operations by which, by means of counting of the subsequently occurring angle transmitter signals until further exceeding a limit value or subsequently falling below a limit value, the size and actual or probable position of the object which is the cause are recorded. Moreover the first signal is checked when the angle sensor signals are absent and rapid stopping is performed, for which reversal REV is also triggered. Again, during reversal REV, the sensor signals are evaluated accordingly. The primary criterion for ending reversal REV is proof that the unwanted object has been conveyed in front of the sensor region on the input side, that is, the signal has dropped below the corresponding detection threshold again. In this state the apparatus is stopped and the position and possible size of the object are signaled on the display panel D.
One particular embodiment of the device includes a pivot drive 50 of the sensor device 1 which is driven with forward and reverse control signals V, R by the control device PC when its pick-up range is to be displaced to the input side or to the chopper side of the conveying zone. Also, for the normal foreign body detection mode there is a pivot position in which optimum compensation of the unwanted signals by moving machine parts is achieved. For this purpose the unwanted signal levels, during passage of the sensor device 1 in the conveying mode, are analyzed in correlation to its position and then the respective pivot position is adjusted at which the lowest interference level was detected. During further operation this position is periodically checked by incremental variation and adapted to the respective conditions. In particular when the thickness of the stream of material conveyed from the pressure roller to the driven conveying roller varies, the compensation ratios vary slightly, which is allowed for by continuous rechecking of the compensation setting.
FIG. 5 shows the input of a signal by a key T which is triggered by a circuit for testing purposes of the rapid stop device SS. The angle transmitter pulses are counted to form a limit value or for subsequent checking of the switching device, which occurs from triggering until stopping. The stop device SS consists of a rapidly excited electromagnet EM whose yoke carries a latch K which cooperates with switching teeth Z of a quick-action coupling ring gear SK.
Other objects, features and advantages will be apparent to those skilled in the art. While a preferred embodiment of the present invention have been illustrated and described, this has been by way of illustration and the invention should not be limited except as required by the scope of the appended claims.
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A conveying device for material to be chopped with conveying rollers comprises a foreign body detection device and a chopper mechanism whose signals are fed to a control device which controls rapid stopping of the conveying rollers when a foreign body detection signal exceeds a predetermined threshold. Upon reversing operation of the conveying rollers, the detection device is used to end the reversing operation when the foreign body is positioned in front of the conveying rollers.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of prior application Ser. No. 614,972, filed May 29, 1984, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to suspension bridges and more particularly to a streamlined box girder type suspension bridge for dispersing live loads applied to a deck.
2. Description of the Prior Art
Stiffening girder type suspension bridges are generally classified into several types, the primary types of which are a box girder, a plate girder, a truss girder and the like.
Of these stiffening girder types, the stream-lined box girder type has recently been most utilized for suspension bridges of a long span for the reasons as will be described hereinbelow.
One of the advantages of the box girder type is the reduction in wind drag on the deck to one third of that for the truss girder type. Furthermore, the box girder type has higher torsional stiffness, weight for weight, than any other types and therefore is convenient to deal with aerodynamic oscillations. Still further, the steel in the box section is capable of resisting stresses in several directions simultaneously, i.e., shear, torsion, lateral bending and the like, serving to save in weight of steel and consequently to reduce the cost of overall bridge construction.
Among the prior art box girder type bridges, a streamlined box girder type proposed by Gilbert Roberts (Canadian Pat. No. 678,259) is well known. A bridge embodying Roberts' streamlined box girder type suspension bridge is known as the Severn Bridge of England built in 1966.
Roberts' streamlined box girder suspension bridge attempts to achieve stability against the wind by streamlining the girder cross section, and is basically based on a design concept of approximating the girder cross section to a slender streamline shape by reducing the girder depth as much as possible on the premise that the structural strength of the box girder is maximally utilized.
In the conventional truss stiffened girder suspension bridges, the girder depth becomes inevitably large because the girder rigidity is increased by trusses, thus proving economically disadvantageous compared to the streamlined box girder type. On the other hand, this type bridge is advantageous in that the bridge is less likely to be affected by the wind despite its large girder depth as the wind easily passes through the truss intervals.
Compared to such truss stiffened girder structure, the streamlined box girder type has various advantages since the girder strength is fully utilized because of the inherent rigidity of the box girder structure as above discussed. These advantages are; radically reduced volume and weight of steel by the reduction in girder depth; stability against the wind arising from the streamlined girder cross section; and extremely easy maintenance of the bridge such as painting.
Despite such several advantages of the streamlined box girder suspension bridge as above enumerated, there still exists a grave problem in this type suspension bridge that the bridge structure becomes extremely sensitive against the live loads and the wind drag. This problem is grave enough to offset the economic advantages over the truss girder type such as the radical reduction in the plate thickness and volume of steel used. To cite an example, if the weight of girder per se is decreased for purposes as mentioned above, aeolian oscillation or buffeting of fine amplitude generates to the girder by the constant wind of even a comparatively low velocity in addition to the rapid increase of traffic vibrations caused by live loads. The light weight and box shaped cross section of this type of girders deteriorate the damping capacity of the girder in absorbing the vibrations through its structure compared to the truss girder. A comparatively large stress repeatedly acts on the hangers and girders, thereby causing damage to the hangers or girders.
As the streamlined box girder type suspension bridge has the girder cross section which is streamlined like wings, if a comparatively large wind which occurs only infrequently acts on the girder and causes dangerous oscillation, the aerodynamic stability of the bridge reaches the maximum and destroys the bridge. This is called the bending-torsional flutter where bending and torsion occur to the girder concurrently.
Thus, the streamlined box girder type suspension bridge contains two contradictory elements; one is the economical advantage of achieving the dynamic stability without increasing thickness of the girder cross section since the cross section is streamlined to reduce the wind resistance; another is that the reduced inherent resistance against external oscillation elements with the less girder weight as the depth and plate thickness are reduced in size as well as the likelihood of catastrophic vibration such as bending-torsional flutter caused by the slender wing-like streamlined shape of the girder cross section.
SUMMARY OF THE INVENTION
The present invention offers a perfect streamlined box girder type suspension bridge by obviating the disadvantages which the stiffening girder type suspension bridge inherently contains and enabling a full use of its advantages.
Basically, the present invention obtains the static design conditions in the initial stage of static design which determine if the girder cross section is within the scope of permissible stresses or not under live loads such as moving vehicles or wind drag; it also analyzes the dynamic design conditions such as the onset wind velocity for the bending-torsional flutter which is induced by comparatively large but infrequently encountered wind and which may damage the girders. The invention then preliminarily adds to the girder weight obtained in the static design the weight necessary for controlling various aeolian oscillations as mentioned above as an additional mass.
When the means of adding the weight for oscillation control to the streamlined box type girders is contemplated as the dynamic design condition, there are two methods for adding the weight. One is adding in the stage of static design the mass secondarily to the girder which has been designed as having sufficient strength, the mass being materials as concrete, water or sand which is irrelevant to the girder strength. Another method is to add the weight necessary for dynamic design conditions so as to correct the girder conditions which have been determined by the static design conditions by increasing the girder depth or the plate thickness.
Of the two methods of adding weight to the girder, the first method according to the present invention places at an appropriate point in the girder cross section the mass by the amount necessary for controlling oscillations calculated under the dynamic design conditions, the mass being such that would not directly contribute to the strength of the girder which had been designed as having sufficient strength in the static design stage. Therefore, it suffices in the present invention if the girder structure is made to have the small girder depth, light weight and sufficient rigidity within the scope of the static design conditions to effectively utilize the advantages of the streamlined box girder.
By adding the mass to the girder cross section obtained in the stage of static design in such a way as to increase the weight of the girder, the present invention aims at extending the scope of durability against the onset velocity of bending-torsional flutter which is considered to occur frequently particularly in the streamlined box girder suspension bridge.
In order to delineate the properties of the bending-torsional flutters and to calculate the velocity which manifests bending-torsional flutters to the girder, Selberg's empirical formula may be modified as follows: ##EQU1##
In the above formula, V represents the expected onset velocity of the bending-torsional flutters, m·Iθ the mass and the polar moment of inertia per unit length of the girder respectively, ωη and ωφ the vertical and torsional circular frequency respectively, B the width of the deck, C the correction factor for cross sectional shape of the girder, the factor being substantially 1.0 if the girder is a slender streamline. In order to improve the durability against the onset velocity of the flutters or to increase V, the girder mass or polar moment of inertia m·Iθ may be increased within the range not to radically decrease torsional circular frequency ωφ or the frequency ratio ωφ/ωη.
In the structure such as a suspension bridge, the above mentioned torsional circular frequency ωφ decreases as the center span increases in length whether the box girder is streamlined or not. This will decrease the onset velocity V of the bending-torsional flutter relatively. The Humber Bridge in England has the longest center span in the world at 1,410 m among the suspension bridges of streamlined box girder type. However, if it is attempted to increase the center span beyond the above length without changing the current streamlined box girder structure, the durability against the onset velocity of the bending-torsional flutter becomes lowered. This is the reason why the center span of 1,410 m for the Humber Bridge is considered the longest achievable for the streamlined box girder type bridge.
The Selberg formula establishes the fact that the girder mass and polar moment of inertia m·Iθ may be increased within the scope not to lower the torsional circular frequency ωφ of the girder in order to raise the onset velocity V of the binding-torsional flutter. Thus, it is considered theoretically possible to extend the center span beyond that of the Humber Bridge for the streamlined box girder suspension bridges built by the current construction method so long as the mass and the polar intertia moment m·Iθ is increased.
As mentioned heretofore, the present invention theorizes that the girder mass and polar moment inertia m·Iθ may be increased by secondarily adding to the girder structure obtained under the static design conditions the mass which is irrelevant to the girder strength. It is also possible to follow other methods such as increasing the girder depth or increasing the plate thickness of steel used to thereby improve the torsional rigidity of the girder and increase the torsional circular frequency ωφ. This results in increased onset velocity V of the bending-torsional flutter.
The basic concept of the streamlined box girder type suspension bridge, however, lies in that the wind resistance is minimized by decreasing the girder depth. When this is taken into consideration, increasing the girder depth in order to enhance the torsional rigidity of the girder will actually result in lowering of correction factor C for the cross sectional shape of the girder expressed by the Selberg formula to about 0.8 even though this may appear to have increased the onset velocity V of the bending-torsional flutter. For instance, if the girder depth is increased to improve the torsional circular frequency ωφ by 20%, then the corrective factor for the cross sectional shape of the girder will decrease by 20%, thus bringing about a result far from the ideal streamlined box girder shaped suspension bridge. On the other hand, if the girder depth is increased, the air separation layer appears along the girder surface as the wind flows along said surface, and this in turn causes limited oscillations called the aeolian oscillation in the stage where the velocity is less than the onset velocity of the bending-torsional flutter. If the oscillation frequency is large, this may lead to a situation where the oscillation frequency may control the resistance of the suspension bridge against the wind.
If increasing the girder depth and enhancing the torsional rigidity of the girder is not an appropriate measure for the streamlined box girder type, then another means of enhancing the torsional rigidity of the girder by increasing the plate thickness of the steel automatically surfaces. However, this means is also defective because if the plate thickness alone was to be increased without increasing the girder depth of the box girder and the same degree of the torsional rigidity was to be imparted to the girder as in the case of larger girder depth, this will necessarily increase the plate thickness and the steel weight to the extent greater than the case of the truss reinforcing material, and consequently increase the cable thickness as well. This measure of increasing the plate thickness and enhancing torsional rigidity of the girder with a far larger steel weight cannot be appropriate and therefore incomparable to the case where the girder depth is increased or when the girders are reinforced by trusses.
Based on the premise that the correction factor C hardly changes in the Selberg formula, the girder mass or polar inertia moment m·Iθ may be increased by using such a material as concrete, water or sand which does not directly contribute to the girder strength, then the onset wind velocity for the bending-torsional flutter may be improved, to result in the construction of a suspension bridge having a far longer center span than that of Humber Bridge even when the currently available streamlined box girder structure is used.
The present invention thus improves the torsional rigidity of the streamlined box girder obtained under the static design conditions as above mentioned by adding appropriate mass which would not directly contribute toward the girder strength and which is within the scope that the torsional circular oscillations of the girder is now lowered. The above mentioned appropriate additional mass is preferably within the range not exceeding 50% of the total weight per unit length of the suspension bridge including girders and cables obtained under the static design conditions.
Provided that the mass to be added is within 50% of the total weight per unit length of the suspension bridge before addition, it was proven through the wind tunnel experiments that the onset velocity for the bending-torsional flutter can be improved by enhancing the torsional rigidity while the economic advantages of the streamlined box girder are fully utilized. If the mass to be added is over 50% of the total weight, the onset velocity is further improved, but the total weight including the girders and cables may exceed that of the truss stiffened girders. This is economically meaningless.
The point where the additional mass is to be positioned is within 1/4 length of the bridge width from the girder center along the bridge axis in view of the effective range which hardly lowers the torsional circular oscillations of the girder.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the present invention will become more apparent from the following description taken in connection with the accompanying drawings in which:
FIG. 1 is a side elevation of the preferred embodiment of the streamlined box girder type suspension bridge according to the present invention;
FIG. 2 is a cross section on a large scale taken along the line II--II of FIG. 1;
FIGS. 3 to 4 show another embodiment of the streamlined box girder type suspension bridge according to the present invention;
FIG. 5 is a graphical representation showing the relation between the total weight and the first symmetric frequency (lowest frequency);
FIG. 6 is a graphical representation showing the effect of total weight on the onset velocity of bending-torsional flutter;
FIG. 7 is a graphical representation showing the relation between the location of the additional mass and onset velocity of the bending-torsional flutter.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Throughout the following description and drawings, like reference numerals designate like or corresponding parts shown in multiple figures of the drawing.
Referring now to the drawings and to FIG. 1 in particular, there is illustrated a streamlined box girder type suspension bridge designated at numeral 1 including a stiffening girder. In the preferred embodiment of the present invention, the stiffening girder of the bridge 1 is constituted by a hollow closed box having streamlined sides, said stiffening girder including a main span 2 of 2,000 m length and side spans 3 of 600 m to 1,000 m length respectively. As shown in this embodiment, a side to center span ratio of this bridge is 0.3 to 0.5.
The stiffening girder is suspended from cables 7 by a number of hangers 8 and supported by a plurality of towers 4. Said towers 4 are emplaced in a spaced relation to each other with a predetermined distance 1 1 . Embedded in a spaced relation to the towers 4 with a predetermined distance 1 2 are abutments 5 at which the end of each of the side spans 3 outside the towers 4 at the extremities of the main span 2 are arranged. The above-mentioned cables 7 are supported by the towers 4 so as to maintain a predetermined sag (f) and anchored to anchorages 6 embedded outside the abutments 5. Tension of the cables 7 is maintained by abutments 5. Said sag span ratio in this embodiment is 1/8.5.
FIG. 2 illustrates in cross section the streamlined box girder type suspension bridge 1. A plurality of internal transverse stiffening frames 9 are arranged in the stiffening girder.
Table 1 below shows the sectional values of the members determined under the static design conditions which comprise the model for the above mentioned streamlined box girder type suspension bridge 1.
TABLE 1______________________________________Elements for Basic DesignSuspension Bridge Models (per bridge)______________________________________Sag Span Ratio -- 1/8.5Side to Center Span Ratio -- 0.5-0.3 Cable Wc t/m 12.5Weight Stiffening Girder Wf t/m 22.0 Total Weight W t/m 34.5Polar Moment of Inertia Iθ t · m · 593.8 s.sup.2 /m Distance of Cable b m 32.0 Sectional Area of Cable Ac m.sup.2 1.39Cable Cable Sag f m 232.9 Horizontal Component Hw t 72592 of the Cable TensionStiffen- Vertical Flexual EI t · m.sup.2 0.17 × 10.sup.9ing RigidityGirder Torsional Rigidity GJ t · m.sup.2 0.14 × 10.sup.9______________________________________
Based on the above suspension bridge model, three different models were assumed by citing three different weights consisting of comparatively inexpensive materials which do not contribute to the girder rigidity.
Weights
ΔW=3 t/m/bridge
ΔW=6 t/m/bridge
ΔW=9 t/m/bridge
The models are shown in Table 2. These three different weights are, as shown in FIG. 2, provided as predetermined mass 11 within a core 12 formed on the stiffening girder cross section at 1 1 1 2 of all the spans of the bridge 1. The additional mass 11 consists of a material such as concrete, and its weight is to be within the range not exceeding 50% of the total weight W (34.5 k/m/bridge) including girders and cables of the basic design bridge model shown in Table 1 per unit length
In this case, the core 12 is arranged centrally symmetrically with respect to the longitudinal axis 10 of the bridge 1 so as to minimize the additional polar moment of inertia of the stiffening girder due to the additional load 11. The concrete may be filled in the core 12 in any desired manner. For instance, it may be cast into the core 12.
FIGS. 3 and 4 show other modifications of the present invention. In FIG. 3, the cores 12 are symmetrically positioned at the predetermined positions on both sides of the girder center. In FIG. 4, the core 12 is formed at the upper portion of the stiffening girder, serving to constitute the deck of the bridge 1.
Table 2 below shows the sectional values of three suspension bridge models to which the three different additional masses 11 are respectively added to the stiffening girder.
TABLE 2__________________________________________________________________________Sectional Values of Suspension BridgeModels to Which Additional Masses areAdded (per bridge)__________________________________________________________________________Sag Span Ratio -- 1/8.5Side to Center Span Ratio -- 0.5-0.3 0.5-0.3 0.5-0.3 Cable Wc t/m 14.0 15.1 16.9Weight Stiffening Girder Wf t/m 22.0 22.0 22.0 Additional Mass ΔW t/m 3.0 6.0 9.0 Total Weight W t/m 39.0 43.4 47.9Polar Moment of Inertia Iθ t · m · s.sup.2 /m 633.0 669.6 708.8 Distance of Cable b m 32.0 32.0 32.0 Sectional Area of Ac m.sup.2 1.55 1.71 1.87 CableCable Cable Sag f m 232.9 232.9 232.9 Horizontal Component Hw t 82061 91319 100787 of the Cable Tension Vertical Flexual EI t · m.sup.2 0.17 × 10.sup.9 0.17 × 10.sup.9 0.17 × 10.sup.9 Rigidity Torsional Rigidity GJ t · m.sup.2 0.14 × 10.sup.9 0.14 × 10.sup.9 0.14 × 10.sup.9__________________________________________________________________________
As shown in FIG. 2, the ratio of the bridge width B and the girder depth D is
B/D=38/6≈6.3
If the girder depth is increased farther and the torsional rigidity improved, there occurs torsional aeolian oscillations of a large frequency to the girder. It is therefore assumed that it is inappropriate to increase the girder depth any farther. Increased girder depth will also act to lower the correction factor C for the cross sectional shape. The total weight 47.9 t/m/bridge per unit length, when the heaviest weight of the above three additional mass 11 (ΔW=9 t/m/bridge) is added according to the present invention, assumes that it is substantially equal to the dead weight of the truss stiffened girder suspension bridge which was designed under approximately same conditions. Therefore, the weight of steel used for the girders per se in the present invention is less than that of the truss girder type, demonstrating an apparent economical advantage.
FIG. 5 shows the relation between the total weight and the lst symmetric frequency for the three types of suspension bridges shown in Table 2. In this figure, the weight 34.5 t/m wherein ΔW=0 represents the weight at the stage of static design without the addition of the mass 11. The figure demonstrates that frequency hardly becomes lowered if the respective masses 11 are added near the center of the box girder.
FIG. 6 shows the onset wind velocity for bending-torsional flutters calculated by the Selberg formula. For simplicity's sake, the correction factor was assumed to be C=0.1. FIG. 6 demonstrates that the total weight increased by adding the mass 11 to the center of box girder will raise the onset velocity of bending-torsional flutter irrespective of the side to center span ratio. The wind velocity which exceeds the onset velocity varies dependant on the natural wind conditions at site. Therefore, the required wind velocities V of 72.5 m/s and 65 m/s are conceived.
Of the additional masses 11, ΔW=9 t/m/bridge was taken up as an example in reviewing the optimum location at which the mass is to be added. FIG. 7 shows the relation between the location Y for adding the mass and the onset velocity of bending-torsional flutter. When the location γ at which the mass is to be added moves farther than about 9 m (or 8.8 m) from the center of the girder, the onset velocity of bending-torsional flutter enters the unstable region as it does not satisfy the prescribed wind velocity 72.5 m/s. Therefore, so long as the location at which the additional mass 11 is to be provided is designed to be within the distance of about 9 m from the center of girder, the value of γ≈9 m is within a stable range which is above the velocity of 72.5 m/s as mentioned above. The value γ≈9 m is somewhat smaller than B/4=9.5 as the bridge width (B) is 38 m. This fact demonstrates that the position to add the mass 11 is effectively elected if γ≦B/4.
On the other hand, if the additional mass is located at γ>B/4, or a point beyond 9 m in FIG. 7, the onset velocity of the bending-torsional flutter begins to decline rapidly. If it goes beyond γ=16 m, it will be less than the onset velocity without the additional mass 11. The above description suggests that the location for the additional mass 11 should preferably be near the center of the box girder. However, it would be more effective in view of construction properties and the above mentioned computation examples that the locations γ be placed symmetrically below (i.e., within) B/4 from the center of the box girder as illustrated in FIG. 3.
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A streamlined box girder type suspension bridge comprises a plurality of towers for supporting the cables, and the center main span and side spans comprising streamlined box girders suspended by a plurality of hangers from the cables. An additional mass of an appropriate weight comprising the material which would not directly contribute to the strength of the box girder is formed as a core at the predetermined portion of the box girder in order to suppress the bending-torsional flutter arising from the streamlined shape of the box girder, and the core extends over the complete span of the bridge symmetrically and with respect to the longitudinal axis thereof.
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CROSS REFERENCE TO RELATED APPLICATIONS
None. However, applicants filed Disclosure Document No. 085,651 on Nov. 7, 1979, which document concerns this application; therefore, by separate letter it is respectfully requested that the document be retained and acknowledgement thereof made.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to textile mills for spinning, twisting and twining and more particularly for machines with rotating rings.
2. Description of the Prior Art
Previous workers in the art have suggested that the ring of a spinning machine be rotated. We have patented a machine with a rotating ring, U.S. Pat. Nos. 3,738,094 and 4,023,340. In each of these machines the drive pulley was located on the level approximately horizontal with the point of mid-travel at the base of the ring. The belt and drive pulley drove a disc which drove the ring by a frictional contact. The belt was elastic and compensated for the difference in distance between the ring pulley and the driven disc as the ring rail reciprocated up and down on the bobbin.
By our U.S. Pat. No. 4,112,666 we disclosed a drive belt trained from the drive pulley on the spindle ring around an idler puller and then around a shell on the ring rail. The idler pulleys moved out and in to compensate for the difference in distance between the drive pulley and the ring rail.
By our patent application, Ser. No. 043,738, filed May 30, 1978 and pending at the time of filing this patent application, we disclosed a drive belt by which a plurality of rings could be tangentially driven from a single belt.
SUMMARY OF THE INVENTION
New and Different Function
According to this invention a drive belt extends from a drive pulley located on the spindle rail below the lowest point of travel on the ring rail to an idler on the draw works support which is above the highest point of travel of the ring rail. Directional pulleys are mounted on the ring rail so that the drive belt is trained around the rings. Since the belt from the drive pulleys to the ring rail and from the ring rail to the draw works is parallel to the vertical movement of the ring rail the total length of the belt will not change and, therefore, it is not necessary to use an elastic belt.
Objects of this Invention
An object of this invention is to spin or twist fibrous yarns for a continuous filament.
Another object is to provide an improved drive for a rotating ring upon a textile machine.
Further objects are to achieve the above with a device that is sturdy, compact, durable, lightweight, simple, safe, efficient, versatile, ecologically compatible, energy conserving, and reliable, yet inexpensive and easy to manufacture, install, adjust, operate and maintain.
Other objects are to achieve the above with a method that is versatile, ecologically compatible, energy conserving, rapid, efficient, and inexpensive, and does not require highly skilled people to install, adjust, operate, and maintain.
The specific nature of the invention, as well as other objects, uses, and advantages thereof, will clearly appear from the following description and from the accompanying drawing, the different views of which are not scale drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective schematic representation of a spinning machine with an embodiment of our invention attached thereto.
FIG. 2 is a side elevational view thereof.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, there is seen illustrated a conventional spinning machine in many respects. Bobbin 10 has yarn 12 being wound thereon. The bobbin is mounted upon spindle 11 which is journalled to spindle rail 14. Bobbin belt 16 is a portion of a bobbin drive means located upon the frame of the spinning machine for rotating the bobbin at high speed. Ring rail 18 is mounted upon the frame for up and down movement or vertical reciprocation relative to spindle rail 14. This vertical reciprocation of the rail 18 is indicated by a double headed arrow. The yarn 12 is threaded from draw works mounted upon draw works support 15 and extends to the bobbin through thread guide 17.
Those skilled in the art will understand that a machine would have a plurality of bobbins thereon and that the ring rail 18 surrounds each of the bobbins. Also, there would be a plurality of draw works not shown here for clarity in thread guides 17 for each bobbin.
Ring 20 is journalled for rotation upon the ring rail 18. Traveler 22 is slidably mounted upon the ring 20 for movement around the ring and around the bobbin 10. Those skilled in the art will understand that the traveler on each ring is for feeding yarn on to each bobbin.
Drive shaft 24 extends the length of the machine. The drive shaft 24 is attached to the spindle rail 14 by any convenient means, e.g., pillow blocks 28 on a bracket 30 attached to the spindle rail. The shaft 24 is driven by main belt 27 from main cylinder of the machine.
Those having ordinary skill in the art will recognize the structure described to this point is old, either being old and conventional in the art or being shown in prior patents, as shown in our prior U.S. Pat. No. 4,112,666 noted above.
A draw works shaft 32 is attached to the draw works support 15 by a plurality of brackets 34 only one of which is illustrated for clarity. A draw works idler 36 is journalled to the draw works shaft 32 for each drive pulley 26.
A drive directional pulley 38 is journalled to shaft 40 which is attached to the ring rail 18 by directional bracket 42. Draw directional pulley 44 is journalled to shaft 46 which is also attached to the directional bracket 42.
Ring belt 50 is trained around drive pulley 26 and extends to the drive directional pulley 38. From there it extends around third directional pulley 48 to around at least one ring 20. From there it extends around the draw directional pulley 44 to the draw idler 36 and back to the drive pulley 26.
In the drawing or ring belt 50 is illustrated as extending around a plurality of rings 20. It will be understood that the drive belt could extend around two rings without any particular or special arrangements. Also, it will be understood that according to our disclosure in our pending application, noted above, it could extend around as many as six rings or more.
If desired, an additional mid-point or frame idler 52 could bear against the belt as the belt extends from the draw works idler 36 to the drive pulley 26. Besides being adjustable so that tension on the belt 50 could be maintained to a desirable level at all times, the additional idler 52 would reduce any vibration or flapping of the belt.
Analysis of the apparatus will show that the ring belt 50 from the drive pulley 26 to the drive directional pulley 38 could be designated as drive portion 54. Also, that portion of the belt 50 extending from draw directional pulley 44 to the draw works idler 36 could be designated as draw portion 56 for the purpose of analysis. Therefore, it may be seen that if the drive portion 54 is parallel to the up and down motion of the ring rail 18 and if the draw portion 56 is also parallel to this up and down motion, the length of the belt will not change as the ring rail 18 moves up and down. Of course, this parallel relationship could be expressed as the ring rail is caused to move up and down parallel to the portions 54 and 56.
The reason the length of the belt will not change is because as portion 54 decreases, the portion 56 increases the same amount. I.e., the sum of the length or the distance of the portion 54 plus the length or distance of the portion 56 is always the same which is to say that the sum of these two distances is a constant. The ring belt is always kept taut by keeping the length of the belt 50, i.e., the distance it extends around the various pulleys the same.
As an aid to correlating the terms of the claims to the exemplary drawing, the following catalog of elements is provided:
______________________________________10 bobbin 30 bracket, spindle rail11 spindle 32 shaft, draw works12 yarn 34 bracket, draw works14 spindle rail 36 idler, draw works15 draw works support 38 drive directional pulley16 bobbin belt 40 shaft17 thread guide 42 bracket, directional18 ring rail 44 draw directional pulley20 ring 46 shaft22 traveler 48 third directional pulley24 drive shaft 50 ring belt26 drive pulley 52 frame idler27 belt, main 54 drive portion28 pillow block 56 draw portion______________________________________
The embodiment shown and described above is only exemplary. We do not claim to have invented all the parts, elements or steps described. Various modifications can be made in the construction, material, arrangement, and operation, and still be within the scope of our invention. The limits of the invention and the bounds of the patent protection are measured by and defined in the following claims. The restrictive description and drawing of the specific example above do not point out what an infringement of this patent would be, but are to enable the reader to make and use the invention.
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The revolving ring on a spinning machine is rotated by a belt encircling the bottom of the ring holder. The drive pulley is located below the ring upon the spindle rail. An idler is mounted upon the draw works support and directional pulleys are mounted upon the ring rail so that as one portion of the belt from the drive pulley to the ring rail is decreased, that portion of the drive belt from the ring rail to the draw works is increased.
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FIELD OF THE INVENTION
[0001] The present invention is directed generally to fiber optical devices, and more particularly to an approach for mounting optical elements used in the fiber optical devices.
BACKGROUND
[0002] Optical fibers find many uses for directing beams of light between two points. Optical fibers have been developed to have low loss, low dispersion, polarization maintaining properties and can be incorporated into several different types of devices, such as amplifiers, filters, lasers and interferometers. As a result, optical fiber systems find widespread use, for example in optical communications.
[0003] However, one of the important advantages of fiber optic beam transport, that of enclosing the optical beam to guide it between terminal points, is also a limitation. There are several optical components, important for use in fiber systems or in fiber system development, that are not implemented in a fiber-based form where the optical beam is guided in a waveguide. Instead, these optical components are implemented in a bulk form, and through which the light propagates freely. Examples of such components include, but are not limited to, filters, isolators, circulators, polarizers, switches and shutters. Consequently, the inclusion of a bulk component in an optical fiber system necessitates that the optical fiber system have a section where the beam path propagates freely in space, rather than being guided within a fiber.
[0004] Free space propagation typically requires use of collimation units at the ends of the fibers to produce and receive collimated beams. In some units, the same focusing element is used to collimate the beams from two different fibers placed at different positions relative to the axis of the focusing optic. This produces collimated beams that propagate in non-parallel directions. The nonparallel propagation of the collimated beams introduces extra issues for aligning the components of the device, and may place some limits on making the device smaller in size.
[0005] A fiber optical device typically includes a collimation unit at each end, to produce a collimated light beam in the region of free-space propagation. The collimation unit typically includes one or more lenses to collimate the light passing to or from a fiber. Bulk optical elements, such as filters, polarizers, and isolator units having birefringent elements and non-reciprocating elements, are disposed in the collimated light beam, or light beams to perform the desired function. The placement of these elements in the collimated light beams is important, since the position along the beam or angle relative to the beam may affect the operation of the device. There is a need, therefore, to ensure that the elements are mounted at the desired position and orientation, and that the desired position and orientation are maintained over a range of possible operating temperatures.
SUMMARY OF THE INVENTION
[0006] Accordingly, there is a need for an improved approach to mounting optical elements in a fiber optic device that improves the positioning and orientation of the element and that reduces the temperature dependent variation of the position and orientation.
[0007] One embodiment of the invention is directed to a method of mounting an optical element to a mount for use in a predetermined temperature range, where the mount has a protruding tip contact region on a mounting surface. The method includes providing adhesive between the optical element and the mounting surface, and pressing the optical element into contact with the protruding contact tip region thereby substantially expelling the adhesive from between the optical element and the protruding contact tip region. The adhesive is cured at a temperature exceeding the predetermined temperature range.
[0008] Another embodiment of the invention is directed to an optical device for use in a predetermined temperature range. The device includes a mount having a first mounting surface provided with a protruding tip contact region, where the protruding tip contact region defines a mounting plane. An element to be mounted has a second mounting surface contacting the protruding tip contact region. Adhesive is attachingly disposed between portions of the first and second mounting surfaces not in mutual contact.
[0009] Another embodiment of the invention is directed to a fiber optic device that includes a mount having a first mounting surface defining a first mounting plane. An optical element is adhesively surface mounted to the first mounting surface of the mount, a second mounting surface of the optical element contacts the first mounting surface of the mount so that the second mounting surface is parallel to the first mounting plane.
[0010] The above summary of the present invention is not intended to describe each illustrated embodiment or every implementation of the present invention. The figures and the detailed description which follow more particularly exemplify these embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The invention may be more completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which:
[0012] [0012]FIG. 1 schematically illustrates a fiber optic communications system in which a tap is used to split off light for monitoring the optical signal on an optical fiber, according to an embodiment of the present invention;
[0013] [0013]FIG. 2 schematically illustrates an embodiment of a fiber optic tap monitor according to the present invention;
[0014] [0014]FIG. 3 schematically illustrates an embodiment of a WDM device according to the present invention;
[0015] [0015]FIG. 4 schematically illustrates a partial cross-section of a conventional fiber optic device;
[0016] [0016]FIG. 5A schematically illustrates an exploded view of a dual fiber collimator according to an embodiment of the present invention;
[0017] [0017]FIG. 5B presents a cross-sectional view of the lens/filter mount illustrated in FIG. 5A;
[0018] [0018]FIGS. 6A and 6B schematically illustrate a partial cross-section of a lens/filter mount, before and after mounting an optical element respectively, according to an embodiment of the present invention;
[0019] [0019]FIG. 7A schematically illustrates a conventional mount showing problems arising from a varying thickness in an adhesive layer;
[0020] [0020]FIG. 7B schematically illustrates an embodiment of the present invention showing that the optical element lies in the mounting plane; and
[0021] [0021]FIG. 8 schematically illustrates another embodiment of a mount for mounting an optical element according to the present invention.
[0022] While the invention 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 the invention 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 invention as defined by the appended claims.
DETAILED DESCRIPTION
[0023] The present invention is applicable to fiber optic devices, and is believed to be particularly useful with fiber optic devices that include optical elements that are face-mounted within the device. Face-mounted elements include, for example, filters such as may be used in wavelength division multiplexed (WDM) devices or tap monitors, polarizers, birefringent plates, polarization rotators and the like.
[0024] A WDM device is used to combine light at different wavelengths into a single optical signal or, in reverse, to separate different wavelength components of an optical signal. A fiber optic tap is important for extracting a fraction of the light propagating along a fiber so as to permit the optical signal to be monitored. Different types of monitors may be used, including a tap monitor and a channel monitor. In the tap monitor, the tapped fraction of the light is directed to a photodetector to measure the total power in the optical signal. A channel monitor is typically used in multiple channel communications systems, for example, dense wavelength division multiplexed (DWDM) systems. The channel monitor splits the tapped fraction of light into its separate channels and measures the amount of light in each channel individually. This permits the operator to determine whether the power in the multiple channel optical signal is evenly distributed among all optical channels.
[0025] A schematic of an embodiment of an optical communications system 100 is presented in FIG. 1, showing how taps are employed to produce monitor signals. A DWDM transmitter 102 directs a DWDM signal having m 0 channels through a fiber communications link 104 to a DWDM receiver 106 .
[0026] In this particular embodiment of DWDM transmitter 102 , a number of light sources 108 a - 108 m generate light at different wavelengths, λ0, λ1 . . . λm 0 , corresponding to the different optical channels. The light output from the light sources 108 a - 108 m is combined in a DWDM combiner unit 110 , or multiplexer (MUX) unit to produce a DWDM output 112 propagating along the fiber link 104 .
[0027] Light sources 108 a - 108 m may be modulated laser sources, or laser sources whose output is externally modulated, or the like. It will be appreciated that the DWDM transmitter 102 may be configured in many different ways to produce the DWDM output 112 . For example, the MUX unit 110 may include filter multiplexers and/or an interleaver to interleave the outputs from different multiplexers. Furthermore, the DWDM transmitter 102 may be equipped with any suitable number of light sources for generating the required number of optical channels. For example, there may be twenty, forty or eighty optical channels, or more. The DWDM transmitter 102 may also be redundantly equipped with additional light sources to replace failed light sources.
[0028] Upon reaching the DWDM receiver 106 , the DWDM signal is passed through a demultiplexer unit (DMUX) 130 , which separates the multiplexed signal into individual channels that are directed to respective detectors 132 a - 132 m.
[0029] The fiber link 104 may include one or more fiber amplifier units 114 , for example rare earth-doped fiber amplifiers, Raman fiber amplifiers or a combination of rare earth-doped and Raman fiber amplifiers. The fiber link 104 may include one or more DWDM channel monitors 126 for monitoring the power in each of the channels propagating along the link 104 . Typically, a fraction of the light propagating along the fiber link 104 is coupled out by a tap coupler 124 and directed to the DWDM channel monitor 126 . The fiber link 104 may also include one or more gain flattening filters 140 , typically positioned after an amplifier unit 114 , to make the power spectrum of different channels flat. The channel monitor 126 may optionally direct channel power profile information to the gain flattening filter 140 . The gain flattening filter 140 may, in response to the information received from the channel monitor 126 , alter the amount of attenuation of different channels in order to maintain a flat channel power profile, or a channel power profile having a desired profile.
[0030] The fiber link 104 may include one or more optical add/drop multiplexers (OADM) 116 for, for example, directing one or more channels to a local loop. In the particular embodiment illustrated, the OADM 116 drops the ith channel, operating at wavelength λi, and directs it to the local loop 118 . The local loop 118 also directs information back to the OADM 116 for propagating along the fiber link 104 to the DWDM receiver 106 . In the illustrated embodiment, the information added at the OADM 116 from the local loop 118 is contained in the ith channel at λi. It will be appreciated that the information directed from the local loop 118 to the OADM 116 need not be at the same wavelength as the information directed to the local loop 118 from the OADM 116 . Furthermore, it will be appreciated that the OADM 116 may direct more than one channel to, and may receive more than one channel from, the local loop 118 .
[0031] The amount of light being added to the fiber link 104 from the local loop 118 may be monitored and controlled so that the optical power added in the channel at λi is at approximately the same level as the power in the other channels λ0 to λi-1, and λi+1 to λm 0 . The light from the local loop 118 may be passed through a power level controller 142 (plc) that controls the level of power in the channels being added in the OADM 116 . The power level controller 142 may include a variable attenuator to reduce power and/or an amplifier to increase power. A tap 144 extracts a fraction of the light and passes the extracted light to the monitor 146 that detects the power of the light being added in the OADM 116 . The monitor 146 directs a signal to the power level controller 142 which adjusts the power of the light upwards or downwards, depending on the signal received from the monitor 146 , so as to set the power of the light being added at the OADM 116 to be approximately the same as that of the other channels.
[0032] A tap 150 and monitor 152 may also be positioned to monitor the DWDM signal 112 emitted by the transmitter 102 . The monitor 152 may feed back a control signal to the transmitter 102 to control the level of the DWDM signal 112 , based upon the power level detected by the monitor 152 .
[0033] One type of tap monitor 200 is schematically illustrated in FIG. 2, and is described in greater detail in U.S. Pat. No. 09/999,533. The tap monitor 200 includes a dual fiber collimator 201 having a first lens 202 and dual-fiber ferrule 204 . Two fibers 206 and 208 are held in the ferrule 204 , with their ends 206 a and 208 a positioned at a distance from the lens 202 equal to about the focal length of the lens 202 . The ferrule end 204 a, and the fiber ends 206 a and 208 a may be polished at a small angle, approximately 1°-8° or so, to prevent reflections feeding to other elements.
[0034] The lens 202 may be a GRIN lens or may be a lens having a curved refracting surface. For example, the lens 202 may be an aspheric lens. The lens 202 may be formed from glass, an optically transmitting polymer, or other suitable transmitting material. The focal length of the lens 202 is typically in the range 1 mm-5 mm, although it may lie outside this range.
[0035] In the illustrated embodiment, a first light beam 210 , from the first fiber 206 , passes through the lens 202 and is collimated. However, since the beam 210 is not positioned on the lens axis 212 , the collimated beam 214 propagates at an angle, θ1, to the axis 212 . The value of θ1 is typically in the range 1.5°-2.5°, although it is not restricted to this range. The collimated beam 214 is incident on the filter 216 , which has a reflective coating on its front surface 216 a. The reflectivity of the reflective coating is typically high, and may be in the range 90%-99.9%, so that only a small fraction (0.1%-10%) of the power in the beam 214 is transmitted through the filter 216 . The light 218 reflected by the filter 216 is directed to the first lens 202 which focuses the beam 220 to the second fiber 208 . The filter 216 may also transmit a portion of a particular wavelength band or an individual optical channel, to permit monitoring of that wavelength band or individual channel.
[0036] The light 222 transmitted through the filter 216 passes to a photodetector unit 224 , which detects the power of the transmitted beam 222 . The photodetector unit 224 may be a photodiode, or other type of light detecting device. Where the photodetector unit 224 is based on a semiconductor material, the band gap of the semiconductor is advantageously arranged to be less than the energy of the photons being detected. For example, the light entering the tap monitor 200 may be an optical communications signal having a wavelength in the range 1300-1650 nm. Accordingly, the photodetector unit 224 may be based on a semiconducting material that absorbs light in this wavelength range, for example indium gallium arsenide and the like.
[0037] In this particular embodiment, the filter 216 is wedged at an angle, for example around 5°, so that refraction of the transmitted beam 222 by the filter 216 directs the beam 222 along a direction parallel to the optical axis 212 of the first lens 202 , towards the photodetector 224 . The DFC 201 is aligned within a housing 230 , with its axis 212 substantially parallel to the axis of the housing 230 . Therefore, the transmitted beam 222 propagates largely parallel to the housing 230 . The use of a wedged element to produce a light beam propagating parallel to the axis from a dual fiber collimator is discussed further in U.S. patent application Ser. No. 09/999,891, entitled “DUAL FIBER COLLIMATOR ASSEMBLY POINTING CONTROL”, filed on Oct. 31, 2001 and incorporated herein by reference. Typically, the first surface 216 a of the filter has the reflective coating while the second surface 216 b has an antireflection coating.
[0038] In an example of a device as illustrated in FIG. 2, the fibers 206 and 208 have a diameter of around 125 μm and are set in the dual-fiber ferrule 204 at a center-to-center spacing of 125 μm. The lens 202 is aspherical, having a focal length in the range 1.5-2.5 mm, and so θ1 has a value of approximately 1.5°-2.5°. The filter 216 may be based on a substrate formed of glass, such as BK7 or B270 glass, and have a wedge angle of around 4.8°. It is to be understood that the values for the various components provided in this paragraph are provided for illustrative purposes only, and are not intended to limit the invention in any way. For example, the wedge angle of the filter 216 depends on the angle of incidence on the filter face 316 a and the refractive index of the filter glass substrate, and may range from 2°-5° or more. Although the illustrated embodiment includes a wedged filter, the invention is not restricted to the use of wedged filters that parallelize the transmitted light with the lens axis. The light passed through the filter may propagate in a direction non-parallel to the axis 212 .
[0039] Another type of filter-based device, a WDM 300 , is schematically illustrated in FIG. 3. A dual-fiber collimator 301 includes a first lens 302 and a dual-fiber ferrule 304 . The first lens 302 is mounted on a lens/filter mount 317 . Two fibers 306 and 308 are held in the ferrule 304 , with their ends 306 a and 308 a positioned at a distance from the lens 302 equal to about the focal length of the lens 302 . The ferrule end 304 a, and the fiber ends 306 a and 308 a may be polished at a small angle to prevent reflections feeding to other elements.
[0040] A first light beam 310 , from the first fiber 306 , passes through the lens 302 and is collimated. However, since the beam 310 is not positioned on the lens axis 312 , the collimated beam 314 propagates at an angle, θ1, to the axis 312 . For typical systems, the value of θ1 may be around 2°, depending on such factors as the focal length of the lens 302 and the separation between the two fibers 306 and 308 .
[0041] The collimated beam 314 is incident on the filter 316 , which is mounted on the lens/filter mount 317 . The filter 316 reflects a portion of the beam 314 as a reflected beam 318 , and transmits the remainder of the beam 314 as a transmitted beam 322 . The reflected beam 318 is reflected to the first lens 302 which focuses the beam 320 to the second fiber 308 .
[0042] The transmitted beam 322 passes through the filter 316 to a single fiber collimator unit (SFC) 330 . The SFC 330 includes a lens 332 and a fiber 334 that is held in the single fiber ferrule 336 . When used in conjunction with the DFC 301 and the filter 316 , the transmitted beam 322 is focused by the lens 332 into the third fiber 334 as beam 324 . In this embodiment, the third fiber 334 is disposed on the axis 338 of the lens 332 , and the SFC 330 is oriented so that the beam 322 from the DFC 301 is parallel to the axis 338 . The ferrule end 336 a and the fiber end 334 a may be polished at a small angle to prevent reflections feeding back to other elements.
[0043] The filter 316 may have a multilayer dielectric filter coating, typically on the first surface 316 a, with the second surface 316 b having an anti-reflection coating. The filter 316 may transmit a fraction of the light incident from the first fiber 306 to the third fiber 334 . For example, where the light 310 contains light in multiple optical channels at different channel wavelengths, the filter 316 may transmit light in only one or a small number of optical channels, reflecting the remaining light to the second fiber 308 . The filter 316 may also be wedged so that the light 322 that is passed through the filter from the first fiber 302 propagates in a direction parallel to the lens axis 312 .
[0044] A filter-based WDM device 300 may be useful for adding or dropping channels in a multi-channel optical communications system. The device may also be used for combining light at light at different wavelengths into a single output, or for separating light at different wavelengths into different outputs.
[0045] In many situations, it is important for fiber optic devices, including taps and WDMs, that various characteristics such as insertion loss, return loss, etc. be as independent of temperature as possible. In many conventional fiber optic devices, the filter is glued to a holder that positions the filter relative to the collimating lenses. A cross-section of part of a conventional fiber device 400 is illustrated in FIG. 4, which shows a mount 402 having a recess 404 for mounting an optical element, such as a filter, lens, polarizer, birefringent plate, or any other type of bulk optical element that may be used in a fiber optic device.
[0046] A lip 408 in the recess provides a flat surface 410 against which the element 406 may be glued. However, a layer of glue 414 , generally of indeterminate thickness, remains between the flat surface 410 and the element 406 due to capillary action, even after the element 406 has been pressed against the flat surface 410 . The absolute thickness of the layer of glue 414 is typically not well controlled and may vary from assembly to assembly. Furthermore, the thickness of the glue layer 414 may vary around the element 406 so that the orientation of the element relative to the axis 416 is not well controlled. Consequently, even if the mount 402 is fabricated with extremely small tolerances on its mounting faces, the uncertainty in the thickness of the glue layer 414 results in an uncertainty in the orientation of the element 406 , and so the orientation of the mount 402 may have to be adjusted when inserting it into a collimator unit.
[0047] Various factors may affect the thermal stability of the device 400 . For example, where the layer of glue 414 is thicker on one side of the mount 402 than the other, any thermal expansion or contraction may result in a tilting of the element 406 . Also, if the glue 414 is not extremely homogeneous, for example, due to incomplete mixing of the different glue components, different regions of the glue layer 414 may manifest different temperature-dependent thicknesses, which also leads to tilting of the element 406 . Several characteristics of the device 400 , such as return loss and insertion loss, may be critically dependent on the tilt of the element, for example where the element 406 is a filter, and, consequently, may change with temperature. For example, a tilt of one side of a filter through 0.01° may lead to a change in the insertion loss of as much as 0.01 dB.
[0048] It is often advantageous to reduce the temperature dependence of the device characteristics. It is also often advantageous to ensure that the element 406 is mounted with an orientation relative to the mount 402 that is as precise as possible. An exploded view of an embodiment of a DFC 500 that has characteristics with reduced temperature dependence is schematically illustrated in FIG. 5A. The fibers 506 and 508 are mounted within the dual fiber ferrule 502 . The lens 504 may be provided with a flat surface 505 for mounting against a corresponding surface 507 of the lens/element mount 510 using an adhesive. A ferrule sleeve 512 may be attached to the outside of the ferrule 502 and the ferrule inserted in the mount 510 , with the sleeve face 520 against the ferrule-mounting face 522 at the end of the mount 510 . The sleeve 512 is mounted at a distance from the end of the ferrule 502 that ensures that the fibers 506 and 508 are correctly spaced from the lens 504 .
[0049] An optical element 516 , for example a filter, or the like, is mounted to a mounting surface 518 of the mount 510 using an adhesive. The element 516 may have a circular cross-section, but may also have a non-circular cross-section. The illustrated example of filter 516 has a rectangular or square cross-section, which is conveniently fabricated from slicing and dicing a large sheet. An expanded view of a cross-section of the mount 510 is illustrated in FIG. 5B, showing the lens and element mounting surfaces 507 and 518 .
[0050] A cross-section through part of the mount 510 is schematically illustrated in FIG. 6A. The element mounting surface 518 may be provided in a recess 520 , although this is not a requirement. The element mounting surface 518 includes a raised portion 522 and may also include a well 524 on one or both sides of the raised portion 522 . In the illustrated embodiment, a well 524 is provided on one side of the raised portion 522 . The raised portion 522 presents a tip 526 for contacting the element 516 , rather than a flat surface. The element 516 is shown close to the mounting surface 518 , with adhesive 528 disposed between the element 516 and the mounting surface 518 , prior to mounting.
[0051] As the element 516 is forced towards the mounting surface 518 , the adhesive 528 is expelled from the region between the tip 526 and the element 516 until the element 516 contacts the tip 526 . The expelled adhesive 528 flows away from the tip 526 , down one or both sides of the raised portion 522 , and may flow to the well 524 . The well 524 need not be filled with expelled adhesive 528 . Since the tip 526 has a very small area, it is possible to overcome capillary action and expel the adhesive 528 entirely from between the tip 526 and the element 516 , so that the element 516 contacts the tip 526 , as illustrated in FIG. 6B. The lens/filter mount 510 , filter 516 and adhesive 528 are raised in temperature, preferably to a temperature higher than the expected operating temperature of the resulting fiber optic device. The adhesive 528 is then cured at the high temperature.
[0052] After curing, the assembly 530 comprising the mount 510 , element 516 and adhesive 528 is allowed to cool. The adhesive 528 cools under tension. The adhesive 528 has a higher thermal expansion coefficient than the mount 510 . As long as the operating temperature of the assembly 530 is less than the cure temperature, the adhesive 528 remains in tension, pulling the element 516 toward the mounting surface 518 . Since the element 516 is in actual contact with the mounting surface 518 at the contact tips 526 , the element 516 does not move relative to the mount 510 as the temperature changes within the operating range. Consequently, when the operating temperature of the assembly 530 varies, the element 516 does not tilt with respect to the mount 510 , thus reducing the temperature dependence of the device's operating characteristics. For example, where the assembly 530 is employed in a tap monitor, the temperature dependence of the coupling and insertion losses may be reduced as a result of the mounting technique just described.
[0053] One example of a suitable adhesive 528 is type 353 NDT produced by Epotek Corp., Billerica, Mass. This is a two-part epoxy that is cured thermally. Furthermore, the type 353 NDT epoxy is thixotropic, which reduces the ability of the adhesive to flow even under elevated temperatures. Thus, the adhesive does not flow along the surface of the filter 516 while curing. Other types of adhesive that cure at elevated temperatures may also be used.
[0054] In one particular embodiment, the mount 510 was manufactured from a martensitic, Se-doped stainless steel, type 182. The mount 510 was mounted in a jig and the mixed epoxy was applied to the mounting surface 518 . The element 516 , in the form of a multilayer dielectric filter formed on a substrate of B270 glass and presenting a face approximately 1.5 mm×1.5 mm to the mount 510 , was forced against the mounting surface 518 with a force of 1 N, and the jig assembly was inserted into an oven for curing at 120° C. for 30 mins.
[0055] It will be appreciated that other optical elements, and not only an optical filter, may be mounted in a similar manner. For example, the lens 504 may be mounted to the mount 510 in the same way in order to reduce movement of the lens due to changing temperature.
[0056] A useful figure of merit to describe thermal effects is the temperature dependent loss over the range −20° C. −75°C. in other words how much the loss of the device changes between −20° C. and 75° C. Conventional tap monitors typically have a temperature dependent loss in the range 0.1 dB-0.15 dB. A tap monitor of the design illustrated in FIG. 2 was fabricated with the lens and filter mounted as illustrated in FIG. 6B. The temperature dependent loss of that device was measured to be 0.04 dB, significantly lower than other devices.
[0057] Another important advantage of the present invention over conventional approaches to face mounting is illustrated with respect to FIG. 7. In conventional approaches, for example as illustrated in FIG. 4, the thin layer of adhesive between the element and the mount may vary in thickness at different parts of the mount. Consequently, the element may not be oriented correctly relative to the mounting surface, irrespective of the accuracy of the mounting surface relative to the axis of the mount. Therefore, the transmission and reflection spectra of the device may not be as designed, and may differ from part to part. In the approach described herein, the optical element is mounted in contact with the mount, and so the accuracy of the orientation of the face relative to the optical axis is determined by the accuracy of reproducing the mounting face of the mount, and not the uniformity of the adhesive layer.
[0058] [0058]FIG. 7 schematically illustrates a face mount 700 for a filter 702 and a lens 704 . The lens 704 is illustrated as a GRIN lens, although the invention is not so restricted, and the lens 704 may be any other suitable type of lens, for example an aspheric lens. A filter mounting plane 710 is defined by the mounting surface 712 upon which the filter 702 is mounted. Likewise, a lens mounting plane 720 is defined by the mounting surface 722 upon which the lens 704 is mounted. The lens 702 need not be face mounted and may be edge mounted to the inside surface 724 of the mount 700 .
[0059] Using the mounting technique described above, the filter 702 contacts the filter mounting surface 712 and is pulled towards the filter mounting surface by the adhesive 714 . Consequently, the filter surface 702 a lies parallel and immediately adjacent to the mounting plane 710 , and so the angle of the filter surface 702 a relative to the axis 716 is well-controlled.
[0060] The mounting surfaces 518 and 712 were shown to be cylindrically symmetric. However, the mounting surfaces 518 and 712 need not be uniform, for example due to manufacturing tolerances. One example of non-uniformity is that the height of the tip 526 above the well 524 may vary tangentially around the mount 510 . In such a case, the filter 516 may not contact the entire tip region 526 all the way around the mount 510 . The filter 516 does, however, contact at least three points of the raised portion 522 around the mount 510 , which provides sufficient filter/tip contact to prevent the filter 516 from moving relative to the mount 510 under conditions of changing temperature. An advantage of this approach to surface mounting optical elements is that, since the element contacts the mounting surface, the surface of the element lies in the plane defined buy the mounting surface. Accordingly, the precision with which the element's surface is oriented is dependent on the precision of manufacturing the mounting surface.
[0061] A mount 810 having another type of mounting surface 818 is schematically illustrated in FIG. 8. Although the aperture 820 is circular, raised portions 822 , having tips 826 , are positioned at various points around the mounting surface 818 , rather than being provided as a ring. The three highest tips 826 define a mounting plane on which the surface of the element rests. More raised portions 822 may be provided on the surface 818 . A well 824 may extend as a ring around the mount 810 , or individual wells (not illustrated) may be provided close to each raised portion 822 .
[0062] It should be understood that the mount may have a different shape, and need not be cylindrically symmetric. A cylindrical symmetry is useful because the mount can be readily manufactured by turning. Other geometries may be used, for example, the mount may have a square or rectangular cross-section.
[0063] As noted above, the present invention is applicable to fiber optic devices and is believed to be particularly useful in fiber optic devices that use one or more surface-mounted elements. It will be appreciated that the invention is not restricted to mounting filters, but may be used for mounting any surface-mounted optical element. Accordingly, the present invention should not be considered limited to the particular examples described above, but rather should be understood to cover all aspects of the invention as fairly set out in the attached claims. Various modifications, equivalent processes, as well as numerous structures to which the present invention may be applicable will be readily apparent to those of skill in the art to which the present invention is directed upon review of the present specification.
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In an improved approach to mounting optical elements in a fiber optic device, the positioning and orientation of the element are more accurate and the temperature dependent variations of the position and orientation are reduced. The mount has a protruding tip contact region on a mounting surface. Adhesive is supplied between the optical element and the mounting surface, and the optical element is pressed into contact with the protruding contact tip region, substantially expelling the adhesive from between the optical element and the protruding contact tip region. The adhesive is cured at a temperature exceeding the predetermined temperature range. This permits the adhesive to pull the element on to the contact tip region throughout the operating temperature range. This also permits the optical element to contact the mounting surface so that the optical element's surface is oriented parallel to the mounting plane.
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BACKGROUND OF THE INVENTION
This invention relates generally to a method of producing a superconductor having a MBa 2 Cu 4 O 8 (M=a rare earth element) crystallographic phase and, more specifically, to a method of producing a superconductor of metal oxides having the following composition: (M 1-x Ca x )(Ba 1-y Sr y ) 2 Cu 4 O 8 where M is the same as above and x and y each represent a positive number of less than 1.
THE PRIOR ART
There is a known superconducting material composed of MBa 2 Cu 4 O 8 (M=rare earth element). This material has a superconducting transition temperature Tc higher than the boiling point (77 K) of liquid nitrogen and is so stable that it does not decrease in oxygen content at temperatures up to about 850° C.
Such a superconductor has been hitherto prepared by a method which includes pyrolyzing a mixture of raw materials having a composition corresponding to that of the superconductor at a temperature of 930° C. and an oxygen pressure of 100 atm for 8 hours (Nature 336, 660-662 (1988)) or a method in which similar raw material composition is pyrolyzed at a temperature of 800° C. or less for 50 hours or more in the presence of a sodium carbonate catalyst (Nature 338, 323-330 (1989)). These known methods, however, have a problem from the industrial point of view because, in the former method, the pyrolysis must be performed at a high oxygen pressure and, in the latter method, the pyrolysis requires a long period of time and the catalyst contaminates the final superconductor.
SUMMARY OF THE INVENTION
The present invention has been made with the foregoing problems of the conventional methods in view and provides an industrially applicable method for the production of a high Tc superconductor.
In accordance with one aspect of the present invention there is provided a method of producing a superconductor of metal oxides having the following composition:
(M.sub.1-x Ca.sub.x)(Ba.sub.1-y Sr.sub.y).sub.2 Cu.sub.4 O.sub.8
wherein M stands for a rare earth element, x is 0 or a positive number of less than 1 and y is 0 or a positive number of less than 1, comprising the steps of:
subjecting an organic solvent solution containing (a) an alkoxide of the rare earth element M, (b) alkoxides of Ca, Ba and Sr and (c) a copper alkoxide or cupric nitrate to hydrolysis in the presence of water and nitrate ions, thereby forming a hydrolyzed product, said alkoxides of Ca and Sr being present only when x and y are not zero, respectively;
removing the solvent from said hydrolyzed product to obtain amorphous powder;
shaping said powder to form a shaped body; and
pyrolyzing said shaped body at a temperature of 700°-850° C. and a pressure of 0.1-10 atm and in an oxidizing atmosphere to form the superconductor.
In another aspect, the present invention provides a method of producing a superconductor of metal oxides having the following composition:
(M.sub.1-x Ca.sub.x)(Ba.sub.1-y Sr.sub.y).sub.2 Cu.sub.4 O.sub.8
wherein M stands for a rare earth element, x is 0 or a positive number of less than 1 and y is 0 or a positive number of less than 1, comprising the steps of:
subjecting an organic solvent solution containing (a) an alkoxide of the rare earth element M, (b) alkoxides of Ca, Ba and Sr and (c) a copper alkoxide or cupric nitrate to hydrolysis in the presence of water and nitrate ions, thereby forming a hydrolyzed product, said alkoxides of Ca and Sr being present only when x and y are not zero, respectively;
shaping said hydrolyzed product to form a shaped body; and
pyrolyzing said shaped body at a temperature of 700°-850 ° C. and a pressure of 0.1-10 atm and in an oxidizing atmosphere to form the superconductor.
In another aspect, the present invention provides a method of producing a superconductor of metal oxides having the following composition:
(M.sub.1-x Ca.sub.x)(Ba.sub.1-y Sr.sub.y).sub.2 Cu.sub.4 O.sub.8
wherein M stands for a rare earth element, x is 0 or a positive number of less than 1 and y is 0 or a positive number of less than 1, comprising the steps of:
subjecting an organic solvent solution containing (a) an alkoxide of the rare earth element M, (b) alkoxides of Ca, Ba and Sr and (c) a copper alkoxide or cupric nitrate to hydrolysis in the presence of water and nitrate ions, thereby forming a hydrolyzed product, said alkoxides of Ca and Sr being present only when x and y are not zero, respectively;
shaping said hydrolyzed product to form a shaped body; and
pyrolyzing said shaped body at a temperature of 700°-850° C. and a pressure of 0.1-10 atm and in an oxidizing atmosphere to form the superconductor.
In a further aspect, the present invention provides a method of producing a superconductor of metal oxides having the following composition:
(M.sub.1-x Ca.sub.x)(Ba.sub.1-y Sr.sub.y).sub.2 Cu.sub.4 O.sub.8
wherein M stands for a rare earth element, x is 0 or a positive number of less than 1 and y is 0 or a positive number of less than 1, comprising the steps of:
subjecting an organic solvent dispersion containing (a) an alkoxide of the rare earth element M dissolved in the solvent, (b) alkoxides of Ca, Ba and Sr dissolved in the solvent and (c) fine particulate of copper hydroxide to hydrolysis in the presence of water and nitrate ions, thereby forming a hydrolyzed product, said alkoxides of Ca and Sr being present only when x and y are not zero, respectively;
removing the solvent from said hydrolyzed product to obtain amorphous powder,
shaping said powder to form a shaped body; and
pyrolyzing said shaped body at a temperature of 700°-850° C. and a pressure of 0.1-10 atm and in an oxidizing atmosphere to form the superconductor.
The present invention also provides a method of producing a superconductor of metal oxides having the following composition:
(M.sub.1-x Ca.sub.x)(Ba.sub.1-y Sr.sub.y).sub.2 Cu.sub.4 O.sub.8
wherein M stands for a rare earth element, x is 0 or a positive number of less than 1 and y is 0 or a positive number of less than 1, comprising the steps of:
subjecting an organic solvent dispersion containing (a) fine particulate of a hydroxide of the rare earth element M, (b) alkoxides of Ca, Ba and Sr dissolved in the solvent and (c) fine particulate of copper hydroxide to hydrolysis in the presence of water and nitrate ions, thereby forming a hydrolyzed product, said alkoxides of Ca and Sr being present only when x and y are not zero, respectively;
removing the solvent from said hydrolyzed product to obtain amorphous power;
shaping said powder to form a shaped body; and
pyrolyzing said shaped body at a temperature of 700°-850° C. and a pressure of 0.1-10 atm and in an oxidizing atmosphere to form the superconductor.
The present invention further provides a method of producing a superconductor of metal oxides having the following composition:
(M.sub.1-x Ca.sub.x)(Ba.sub.1-y Sr.sub.y).sub.2 Cu.sub.4 O.sub.8
wherein M stands for a rare earth element, x is 0 or a positive number of less than 1 and y is 0 or a positive number of less than 1, comprising the steps of:
mixing an organic solvent, (a) fine particulate of a hydroxide of the rare earth element M, (b) fine particulate of hydroxides of Ca, Ba and Sr and (c) fine particulate of copper with water and nitrate ions, thereby forming a said hydroxides of Ca and Sr being present only when x and y are not zero, respectively;
removing the solvent from said gel to obtain amorphous powder;
shaping said powder to form a shaped body; and
pyrolyzing said shaped body at a temperature of 700°-850° C. and a pressure of 0.1-10 atm and in an oxidizing atmosphere to form the superconductor.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be described in detail below with reference to the accompanying drawings, in which:
FIG. 1 is a powder X-ray diffraction pattern of YBa 2 Cu 4 O 8 obtained in Example 1; and
FIG. 2 is a graph showing superconductivity characteristics in terms of magnetic susceptibility of the superconductor obtained in Example 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In one preferred method according to the present invention, an organic solvent solution containing (a) a rare earth alkoxide, (b) one or more alkaline earth metal alkoxides and (c) copper alkoxide or cupric nitrate is first prepared.
As the rare earth element to be used in the ingredient (a), Y or La is preferably used. If desired, there may be used Sc, Nd, Sm, Eu, Gd, Dy, Ho, Er, Yb, Lu or the like rare earth element. As the alkaline earth metal to be used in the ingredient (b), Ba is used. If desired, Ba is used in conjunction with Sr and/or Ca. As the alcohol for the formation of the alkoxide group in the ingredients (a)-(c), monohydric alcohols such as methanol, ethanol, butanol and hexanol and dialcohols such as ethylene glycol and propylene glycol may be suitably used.
The organic solvent solution may be prepared by dissolving the ingredients (a)-(c) in a common solvent or by first dissolving respective ingredients (a)-(c) in different solvents and mixing the resulting solutions. The preferred method for the preparation of the organic solvent solution includes first dissolving the ingredients (a) and (b) in a solvent to form a first, homogeneous solution with which is then mixed a second solution containing cupric nitrate. This method is advantageous because cupric nitrate can provide nitrate ions and because the concentration of cupric nitrate in the second solution can be made high.
Illustrative of suitable organic solvents for the preparation of the organic solvent solution containing the ingredients (a)-(c) are ethanol, isopropanol, butanol, dioxane, tetrahydrofuran, benzene, toluene, xylene and ethylbenzene.
The contents and the kinds of the ingredients (a)-(c) are so determined as to provide the desired metal oxides. For example, when a superconductor of metal oxides YBa 2 Cu 4 O 8 is to be produced, an organic solvent solution containing an yttrium alkoxide, a barium alkoxide and cupric nitrate (or a copper alkoxide) and having contents of the yttrium and barium alkoxides of about 1 mole and 2 moles, respectively, per 3 moles of cupric nitrate (or copper alkoxide) is prepared.
The thus prepared organic solvent solution containing the ingredients (a)-(c) is then subjected to hydrolysis in the presence of water and nitrate ions, thereby forming a hydrolyzed product. The content of water in the reaction mixture to be hydrolyzed is generally 0.2-5 moles, preferably 0.5-2 mole, per mole of the total of ingredients (a)-(c). The content of nitrate ions in the reaction mixture to be hydrolyzed is generally 0.5-5 moles, preferably 1-2 moles per mole of the total of the ingredients (a)-(c). The nitrate ions and water may be provided by addition of aqueous nitric acid to the organic solvent solution or may be derived from Cu(NO 3 ) 2 3H 2 O added as the ingredient (c). The hydrolysis is generally performed at a temperature from room temperature up to the boiling point of the organic solvent for a period sufficient to form a gel-like hydrolyzed mixture, generally 5-72 hours.
The hydrolyzed product is processed for the removal of the solvent therefrom to obtain amorphous powder. The removal of the solvent may be effected by any known method such as distillation at ambient or an elevated temperature under ambient or a reduced pressure. This powder whose primary particles generally have a particle size of 0.1 μm or less may be used as a precursor for the preparation of superconductors. Thus, the powder is shaped to form a shaped body which is then pyrolyzed to form a superconductor of oxides of the metals of the ingredients (a)-(c). The term "shaped body" used in the present specification and appended claims is intended to refer to wires, powders, filaments, fibers, plates, blocks, pipes, films, coatings and the like molded bodies and composite articles using these materials.
Alternatively, the hydrolyzed product is formed into a desired shaped body, which is then dried and pyrolyzed to form a superconductor. A molding aid formed of a polymeric substance such as carboxymethylcellulose or polyvinyl alcohol may be mixed with the hydrolyzed product.
When the hydrolyzed product or the amorphous powder obtained therefrom is used for the formation of coatings, it is applied over a surface of a substrate. The coated substrate is then heated to effect pyrolysis, thereby to give a composite article having a superconducting surface. The substrate may be formed of an elemental metal such as copper or silver; an alloy such as stainless steel; a metal oxide such as alumina, zirconia, magnesia or strontium titanate; a ceramic material such as silicon carbide; or graphite. The substrate may be in the form of a plate, a block, a coil, a fiber, a fabric, a pipe, a rod or the like shaped body.
The pyrolysis is performed at a temperature of 700°-850° C. and a pressure of 0.1-10 atm, preferably 0.5-2 atm in an oxidizing atmosphere such as an oxygen-containing atmosphere, e.g. air. Since, in the method according to the present invention, the formation of metal carbonates with high decomposition temperatures, such as alkaline earth metal carbonate, can be avoided, the pyrolysis is advantageously carried out at a relatively low temperature. Presumably, a portion of the nitrate ions is incorporated into the hydrolysis product to form an alkaline earth metal nitrate with a relatively low decomposition temperature. The nitrate ion thus bound to the alkaline earth metal would prevent the contact between carbonate ions and the alkaline earth metal and, hence, the formation of an alkaline earth metal carbonate during the course of the pyrolysis.
In another preferred embodiment of the present invention, an organic solvent dispersion containing (a) a rare earth alkoxide dissolved in the solvent, (b) one or more alkaline earth metal alkoxides dissolved in the solvent and (c) fine particulate of copper hydroxide is first prepared.
As the ingredients (a) and (b), those used in the above-described first embodiment may be used. The ingredient (c) may be suitably obtained by hydrolysis of a copper salt solution to precipitate the copper as copper hydroxide. Examples of suitable copper salts include copper sulfate, copper nitrate and copper chloride. The dispersion is preferably obtained by mixing an organic solvent solution containing the ingredients (a) and (b) with an organic solvent dispersion containing the ingredient (c).
The thus prepared organic solvent dispersion is then subjected to hydrolysis in the presence of water and nitrate ions, thereby forming a hydrolyzed product in the form of a gel. The hydrolyzed product is processed for the removal of the solvent therefrom to obtain amorphous powder whose primary particles generally have a particle size of 0.1 μm or less and which may be used as a precursor for the preparation of superconductors.
In a third, preferred embodiment of the present invention, an organic solvent dispersion containing (a) fine particulate of a rare earth element hydroxide, (b) one or more alkaline earth metal alkoxides dissolved in the solvent and (c) fine particulate of copper hydroxide is first prepared.
As the ingredient (b), those used in the above-described first embodiment may be used. The ingredients (a) and (c) may be suitably obtained by hydrolysis of salts (e.g. sulfates, nitrates and chlorides) of a rare earth element and copper, respectively, to precipitate the rare earth element and copper as hydroxides. The dispersion is preferably obtained by mixing an organic solvent solution containing the ingredient (b) with organic solvent dispersions containing the ingredients (a) and (c).
The thus prepared organic solvent dispersion is then subjected to hydrolysis in the presence of water and nitrate ions, thereby forming a hydrolyzed product in the form of a gel. The hydrolyzed product is processed for the removal of the solvent therefrom to obtain amorphous powder whose primary particles generally have a particle size of 0.1 μm or less and which may be used as a precursor for the preparation of superconductors.
In a fourth, preferred embodiment of the present invention, an organic solvent dispersion containing (a) fine particulate of a rare earth element hydroxide, (b) fine particulate of one or more alkaline earth metal hydroxides and (c) fine particulate of copper hydroxide is first prepared. These ingredients (a)-(c) may be suitably obtained by hydrolysis of salts (e.g. sulfates, nitrates and chlorides) of a rare earth element, one or more alkaline earth metals and copper, respectively, to precipitate the rare earth element, alkaline earth metals and copper as hydroxides. The dispersion is preferably obtained by mixing organic solvent dispersions containing the ingredients (a)-(c).
The thus prepared organic solvent dispersion is then mixed with water and nitrate ions, thereby forming a gel. The gel is processed for the removal of the solvent therefrom to obtain amorphous powder whose primary particles generally have a particle size of 0.1 μm or less and which may be used as a precursor for the preparation of superconductors.
In the above embodiments, the term "fine particulate" is intended to refer to particles having a particle size of 1 μm or less, preferably 0.03-0.5 μm.
The following examples will further illustrate the present invention.
EXAMPLE 1
A solution of yttrium butoxide in xylene, a solution of barium ethoxide in ethanol and a solution of cupric nitrate (Cu(NO 3 ) 2 ·3H 2 O) in ethanol were mixed with each other to obtain a raw material solution having an atomic ratio of Y:Ba:Cu of 1:2:4. The raw material solution which contained water in an amount of about 1.7 mol per mol of the total of the metals was then reacted at about 60° C. for 20 hours under reflux in a nitrogen atmosphere with stirring, to obtain a hydrolyzed product mixture containing a gel-like substance. This mixture was evaporated to dryness for the removal of the solvents with heating to obtain amorphous superfine powder.
The amorphous powder was heated to 800° C. at a heating rate of 1° C./minute under oxygen stream of 1 atm and maintained at that temperature for 10 hours. The powder X-ray diffraction analysis of the resultant product is shown in FIG. 1, from which it is seen that the product has a YBa 2 Cu 4 O 8 crystal phase. The magnetic susceptibility of the product is shown in FIG. 2, from which it is seen that the product is a superconductor having Tc of 80 K.
EXAMPLE 2
The amorphous powder obtained in Example 1 was dispersed in acetone and the dispersion was uniformly applied over a surface of MgO substrate. The coating was then calcined at 800° C. for 10 hours in the atmosphere of oxygen, thereby obtaining a composite article having a superconductor film having YBa 2 Cu 4 O 8 crystal phase.
EXAMPLE 3
The gel-like substance-containing mixture obtained in Example 1 was applied over a surface of MgO substrate and dried. The dried coating was then calcined at 800° C. for 10 hours in the atmosphere of oxygen, thereby obtaining a composite article having a superconductor film having YBa 2 Cu 4 O 8 crystal phase.
EXAMPLE 4
Ammonia gas was bubbled through a solution of copper nitrate dissolved in ethanol to obtain fine particulate of copper hydroxide as precipitates. The precipitates were washed with water and dispersed in ethanol to obtain a dispersion. This dispersion was then mixed with a solution of yttrium butoxide in xylene and a solution of barium ethoxide in ethanol to obtain an organic solvent dispersion having an atomic ratio of Y:Ba:Cu of 1:2:4. After addition of nitric acid, the dispersion was hydrolyzed in the same manner as that in Example 1 to obtain a hydrolyzed product mixture containing a gel-like substance. This mixture was evaporated to dryness for the removal of the solvents with heating to obtain amorphous superfine powder. The pyrolysis of the powder was effected in the same manner as that in Example 1 to give a superconductor having YBa 2 Cu 4 O 8 crystal phase.
EXAMPLE 5
Yttrium nitrate was added to an aqueous ethanol to hydrolyze the nitrate and thereby to obtain a first dispersion containing fine particulate of yttrium hydroxide. Barium nitrate was added to an aqueous ethanol to hydrolyze the nitrate and thereby to obtain a second dispersion containing fine particulate of barium hydroxide. Ammonia gas was bubbled through a solution of copper nitrate dissolved in ethanol, thereby to obtain fine particulate of copper hydroxide as precipitates. The precipitates were washed with water and dispersed in ethanol to obtain a third dispersion. The first through third dispersions and were mixed with each other to obtain a fourth dispersion having an atomic ratio of Y:Ba:Cu of 1:2:4. After addition of nitric acid, the fourth dispersion was gel at a temperature of 60° C. for 20 hours to obtain a product mixture containing a gel-like substance. This mixture was evaporated to dryness for the removal of the solvents with heating to obtain amorphous superfine powder. The pyrolysis of the powder was effected in the same manner as that in Example 1 to give a superconductor having YBa 2 Cu 4 O 8 crystal phase.
EXAMPLE 6
Yttrium nitrate was added to an aqueous ethanol to hydrolyze the nitrate and thereby to obtain a first dispersion containing fine particulate of yttrium hydroxide. Ammonia gas was bubbled through a solution of copper nitrate dissolved in ethanol, thereby to obtain fine particulate of copper hydroxide as precipitates. The precipitates were washed with water and dispersed in ethanol to obtain a second dispersion. The first and second dispersions and were mixed with each other to obtain a third dispersion having an atomic ratio of Y:Cu of 1:4 to which was added metallic barium. The barium was reacted with ethanol to form barium ethoxide to give a third dispersion having an atomic ratio of Y:Ba:Cu of 1:2:4. After addition of nitric acid, the third dispersion was hydrolyzed at a temperature of 60° C. for 20 hours to obtain a hydrolyzed product mixture containing a gel-like substance. This mixture was evaporated to dryness for the removal of the solvents with heating to obtain amorphous superfine powder. The pyrolysis of the powder was effected in the same manner as that in Example 1 to give a superconductor having YBa 2 Cu.sub. 4 O 8 crystal phase.
EXAMPLE 7
A solution of yttrium butoxide in xylene, a solution of barium ethoxide in ethanol, a solution of calcium ethoxide in ethanol and a solution of cupric nitrate (Cu(NO 3 ) 2 3H 2 O) in ethanol were mixed with each other to obtain a raw material solution having an atomic ratio of Y:Ca:Ba:Cu of 0.9:0.1:2:4. The raw material solution was reacted at about 60° C. for 20 hours under reflux in a nitrogen atmosphere with stirring, to obtain a hydrolyzed product mixture containing a gel-like substance. This mixture was evaporated to dryness for the removal of the solvents with heating to obtain amorphous superfine powder. The pyrolysis of the powder was effected in the same manner as that in Example 1 to give a superconductor having Y 0 .9 Ca 0 .1 Ba 2 Cu 4 O 8 crystal phase.
EXAMPLE 8
A solution of yttrium butoxide in xylene, a solution of barium ethoxide in ethanol, a solution of strontium ethoxide in ethanol and a solution of cupric nitrate (Cu(NO 3 ) 2 3H 2 O) in ethanol were mixed with each other to obtain a raw material solution having an atomic ratio of Y:Ba:Sr:Cu of 1:1:1:4. The raw material solution was reacted at about 60° C. for 20 hours under reflux in a nitrogen atmosphere with stirring, to obtain a hydrolyzed product mixture containing a gel-like substance. This mixture was evaporated to dryness for the removal of the solvents with heating to obtain amorphous superfine powder. The pyrolysis of the powder was effected in the same manner as that in Example 1 to give a superconductor having YBaSrCu 4 O 8 crystal phase.
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A method of producing a superconductor of metal oxides having the following composition:
(M.sub.1-x Ca.sub.x)(Ba.sub.1-y Sr.sub.y).sub.2 Cu.sub.4 O.sub.8
wherein M stands for a rare earth element, x is 0 or a positive number of less than 1 and y is 0 or a positive number of less than 1, is disclosed, which includes hydrdolyzing an organic solvent solution or dispersion containing (a) alkoxide or fine particulate of a hydroxide of the rare earth element M, (b) alkoxides orfine particulate of hydroxides of Ca, Ba and Sr and (c) alkoxide, nitrate or fine particulate of hydroxide of copper in presence of water and nitrate ions. The alkoxides or hydroxides of Ca and Sr are present only when x and y are not zero, respectively. The hydrolyzed product is then dried, shaped and pyrolyzed to obtain the superconductor.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to fence wall construction and particularly to a fence wall constructed by a combination of precast concrete elements which results in a strong and aesthetically pleasing structure.
2. Description of the Prior Art
In the past, fences and retaining walls have primarily been constructed by hand, one piece at a time, through the combination of mortar and brick. The largest single unit of construction was the brick itself. As a result, the process was very slow and labor intensive requiring masons and skilled workers with a a high degree of experience and proficiency. In many cases, the costs of labor exceeded the cost of raw materials used in building the fence.
The present invention provides a prefabricated concrete fence made up of precast units which can be assembled in various combinations to effectively reproduce the appearance of previous brick and stone fences and walls. In the present method, a single semi-skilled worker can assemble fence columns from units that are six to eight times as large as a single brick. Precast panels are used to span the distance between completed columns and are more than one hundred thirty times the size of a single brick.
The precast units can be provided in an infinite number of patterns and color combinations. The end result is a fence wall structure which can be erected at a substantial savings in time and material cost while achieving a permanent, maintenance free, aesthetically pleasing fence or wall.
SUMMARY OF THE INVENTION
In the method of the invention, a wall is constructed utilizing precast concrete elements by first installing a plurality of column foundations at selected, spaced-apart locations. A vertical column is then erected on each column foundation by stacking a series of precast concrete elements. Each element has a pair of lateral edges which are separated by a pair of vertical edges. The lateral edges of adjoining elements are joined by a mortar joint to form a vertical column. The vertical column has an open interior which defines an upright passage within the column and a pair of oppositely arranged, vertically extending recesses which extend along the vertical edges of the elements. Concrete is then poured through the upright passage to fill the open interior and form a completed column. The distance between two completed columns is spanned by sliding a panel within the column vertical recesses, the panel having vertical edges which are adapted to matingly engage the column vertical recesses.
Preferably, a reinforcing member is installed atop selected precast concrete elements within the vertical column. Each reinforcing member is located within the mortar joint between adjoining elements of the vertical column and a portion of the reinforcing member extends transversely across the open interior of the column.
The column vertical recesses can be fashioned by erecting a pair of spaced-apart end members on each column foundation, each end member having an interior surface, an exterior surface, and a length which extends vertically upward from its respective foundation. The interior surface of each end member is surrounded by a thin membrane to facilitate later removal of the end member from the column. The end members are erected plumb and level prior to stacking the precast concrete elements to properly orient the completed column.
Additional objects, features and advantages will be apparent in the written description which follows.
BRlEF DESCRIPTION OF THE DRAWING
The novel features believed characteristic of the invention are set forth in the appended claims. The invention itself; however, as well as a preferred mode of use, further objects and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
FIG. 1 is an isolated view of a vertical column used in the method of the invention, the column being partly broken away for ease of illustration.
FIG. 2 is a cross-sectional view of a completed vertical column taken along lines II-II in FIG. 6.
FIG. 3 shows a reinforcing member used in a corner column of the wall, the wall elements being shown in dotted lines.
FIG. 4 is a view similar to FIG. 3 showing a reinforcing member used in a column located at a wall intersection.
FIG. 5 is a view similar to FIG. 4 showing the reinforcing member used in an intermediate column of the wall.
FIG. 6 is a partial, perspective view of the wall constructed utilizing the method of the invention with portions broken away.
DETAILED DESCRIPTION OF THE INVENTION
The method of the invention is applicable to all types of ornamental and utilitarian walls and fences including retaining walls, privacy walls and fences, and the like. The terms "wall" and "fence" are used interchangeably. The wall is first located with reference to building property or lines set out to determine the location of the wall. Using conventional practice, points are located for the foundations of the vertical columns, the column locations being separated by predetermined distances according to, e.g. the property lines, length of the wall, etc. The earth is then excavated to comply with engineering specifications for the vertical columns in accordance with local building codes and manufacturer's requirements. The column foundations can be either round, square, rectangular, or piers. The elevation of each foundation is determined and noted and reinforcement is placed in the excavation and stabilized. Concrete is then poured into the excavation and brought to the predetermined elevation. Preferably, two eight foot reinforcement rods are positioned within the foundation and extend vertically upward therefrom.
A vertical column is then erected on each column foundation by stacking a series of precast concrete elements upon the foundation. Although the precast elements can comprise precast concrete blocks of square or rectangular shape and having open interiors to receive the rebar rods 11, 13, the columns are preferably formed by stacking a series of precast plates (21, 23 in FIG. 1). A typical plate is twenty inches wide, three inches thick and twelve inches high. The plates can be precast in forms or molds in a variety of decorative appearances, such as the brick-like appearance shown in FIG. 1.
In order to orient the plates 21, 23, a pair of end members 17, 19, are erected plumb and level and braced in the exact location to be flush with the panel ends 25, 27. The end members can be posts of steel, wood, plastic, or other available materials. In FIG. 1, end member 19 is made up of a pair of 2×4's which are braced with boards 29, 31. The end member 17 is a piece of channel iron which is braced by metal rods 33, 35, 37. A thin membrane, such as felt strip 39 is placed on the interior surface 41 of each end member 19 to facilitate later removal of the end members.
A thin bed of mortar is then placed on either side of the foundation 15 along lines parallel to the longitudinal axis of the wall. The distance between each line of mortar is determined by the width of the end members 17, 19, plus the width of a mating pair of plates 21, 43. Plates 21, 43 can now be placed on the beds of mortar and brought to level in both the horizontal and vertical planes. A small restraining band, such as a wire band, can then be wrapped around each mating pair of plates 21, 43 and made secure.
A bed of mortar can then be placed on the lateral edges 45, 47 of the two plates 21, 43, and a specially designed reinforcing member (49 in FIG. 5) can now be placed across the top edges of the plates 21, 43 and embedded into the wet mortar. As shown in FIGS. 3-5, the reinforcing members 49, 51, 53 are located within the mortar joint between adjoining plates of the vertical column with a portion of each reinforcing member (55 in FIG. 5) extending transversely across the open interior 57 of the column. A new panel (23 in FIG. 1), can now be placed on the mortar joint atop the first panel 21, leveled and secured. This same procedure is repeated until the desired column height is reached. The open interior 57 of the column is then filled from the bottom of column to the top with concrete to create an integral, structural column.
When the columns have reached sufficient strength, the retaining bands and end members 17, 19 are removed, thereby creating a pair of oppositely arranged, vertically extending recesses which extend along the vertical edges 63 of the plates. The distance between two completed columns (65, 67, in FIG. 6) is then spanned with a series of horizontal, precast panels 69, 71, 73. The first precast panel 69 is inserted within the mating vertical recesses 61, 75 of columns 65, 67. The panel is brought to level either with shims or mortar. The top edge 77 of the panel is then covered with a bed of mortar and the next succeeding panel 71 is inserted into the vertical recesses 61, 75 and lowered into place. In the event that mortar is not capable of supporting the weight of the panel, shims or spacers can be used to maintain the proper spacing. This procedure is repeated until the desired wall height is achieved. A typical panel is approximately, but not limited to, nine feet in length, two feet in height and three inches thick. The walls and columns can be capped, if desired, with a variety of available precast caps of brick, stone, metal, or plastic.
An invention has been provided with several advantages. The column plates are small enough to be easily handled by one person and are light enough to be erected in the same manner as brick. The intermediate wall or horizontal panels can be easily installed with a small tractor or mechanical lift. The horizontal panels can be removed and replaced if damaged. By using precast units, a fence can be quickly and easily erected with minimum labor expense using semi-skilled workers.
While the invention has been shown in only one of its forms, it is not thus limited but is susceptible to various changes and modifications without departing from the spirit thereof.
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A method of constructing a wall is shown in which vertical columns are erected by stacking a series of precast concrete elements. The elements are spaced-apart by temporary end members to define an upright passage within the column. Concrete is poured within the passage to fill the column interior. After the concrete hardens, the end members are removed to provide oppositely arranged, vertically extending recesses on the column exteriors. The distance between two completed columns is spanned by sliding a precast panel within two of the columns vertical recesses.
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BACKGROUND OF THE INVENTION
This invention relates to wall-mounted hangers for hanging a picture frame that is provided with a hanging wire at the back of picture frame.
More specifically, this invention relates to picture frame hangers that can be fabricated from continuously bending of a metal strip, and can be attached to walls, such as dry walls by driving a nail through the hanger and into the wall in inclined position.
Many picture frames have a hanging wire attached to the back of the picture frame. A variety of wall-mounted hangers in prior art have been proposed for suspending the hanging wire of the picture frame onto the wall. The hangers in prior art mainly consist of an anchor section in the upper part of the hanger, and a hook section in the lower part of the hanger. The anchor section allows a fastener such as a nail to drive through the hanger, and mount the hanger onto the wall. The hook section forms an U-hook for suspending and retaining the hanging wire of the picture frame. In prior art, a lateral projectile is commonly provided in the anchor section, which guides the nail driving through the hanger and entering into the wall in inclined position. The inclined position of the nail offers the advantages of enhancing the loading capacity of the hanger, preventing the hanger from swiveling or pivoting about the nail, and preventing the nail from sliding out of the wall. The anchor section of the hanger is located directly above the hook section of the hanger. The hangers are commonly fabricated from continuously bending of a metal strip. The above described hangers in prior art can be found in U.S. Pat. Nos. 1,675,281, 3,226,065, 2,137,837, 2,454,813, 2,940,712, and 5,267,719, . . . etc. FIG. 1 illustrates the hanger in prior art that is disclosed in U.S. Pat. No. 1,675,281.
There is a significant drawback of the above hangers in prior art because the anchor section of the hanger is located directly above the hook section of the hanger. When hanging a picture frame onto the hanger, a person can hardly see the hanger behind the picture frame when he or she is holding the picture frame against the wall and the hanger. Therefore, it is a common practice for a person to hold the picture frame against the wall and above the hanger, and then slide the picture frame downward against the wall in an effort to approach the hanger from the top of the hanger. Unfortunately, the lateral projectile in the anchor section becomes an obstacle that blocks the entrance to U-hook in the hook section of the hanger. As a result, it requires a person to take time and effort to engage the hanging wire into the U-hook of the hanger. Frequently, the hanging wire can be mistakenly hung onto the top of lateral projectile of the anchor section rather than the U-hook of the hook section. The picture frame is therefore unstably hung onto the hanger, and can easily slip out of the hanger.
Therefore, there is a need to provide a picture frame hanger capable of being fabricated from continuously bending of a metal strip, capable of being attached to wall by driving a nail through the hanger and into the wall in inclined position, and capable of engaging the hanging wire of the picture frame into the hook section of the hanger without interference from the anchor section of the hanger.
SUMMARY OF THE INVENTION
An object of the invention is to provide a hanger having an anchor section in the lower part of the hanger for driving a nail through the hanger and into the wall in inclined position, and having a hook section in the upper part of the hanger for suspending and retaining the picture frame hanging wire.
Another object of the invention is to provide such a hanger, in which the hanging wire of the picture frame directly engages into the hook section of the hanger without interference while sliding the picture frame downward against the wall and approaching the hanger from the top of hanger.
Another object of the invention is to provide such a hanger capable of being fabricated by continuously bending of a metal strip.
Another object of the invention is to provide such a hanger that does not pivot or swivel about the anchoring nail.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a picture frame hanger of prior art.
FIG. 2A is a perspective view of the first preferred embodiments of the invention.
FIG. 2B is a sectional view of the first preferred embodiments of the invention.
FIG. 3A is a perspective view of the alternative form of the first preferred embodiments of the invention.
FIG. 3B is a sectional view of the alternative form of the first preferred embodiments of the invention.
FIG. 4A is a perspective view of the second preferred embodiments of the invention.
FIG. 4B is a sectional view of the second preferred embodiments of the invention.
FIG. 5A is a perspective view of the third preferred embodiments of the invention.
FIG. 5B is a sectional view of the third preferred embodiments of the invention.
FIG. 6A is a perspective view of the fourth preferred embodiments of the invention.
FIG. 6B is a sectional view of the fourth preferred embodiments of the invention.
FIG. 7A is a perspective view of the fifth preferred embodiments of the invention.
FIG. 7B is a sectional view of the fifth preferred embodiments of the invention.
FIG. 8A is a perspective view of the sixth preferred embodiments of the invention.
FIG. 8B is a sectional view of the sixth preferred embodiments of the invention.
FIG. 9A is a perspective view of the seventh preferred embodiments of the invention.
FIG. 9B is a sectional view of the seventh preferred embodiments of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a picture frame hanger of prior art. The hanger has a lateral projectile at the top of hanger that forms an anchor section of the hanger. The lateral projectile guides nail driving through the anchor section of the hanger and into the wall in inclined position. Such lateral projectile blocks the entrance to the U-hook below when the hanging wire of a picture frame approaches the hanger from the top of hanger.
FIG. 2A and FIG. 2B show the first preferred embodiments of the picture frame hanger of the invention. The hanger 1 of the invention comprises of a first vertical leg 2 , a first bend 3 , a second inclined leg 4 , a second bend 5 , a third inclined leg 6 , a third bend 7 and a fourth vertical leg 8 . The first vertical leg 2 has a frontward vertical surface 9 and a rearward vertical surface 10 . The fourth vertical leg 8 has a frontward vertical surface 11 and a rearward vertical surface 12 . Both rearward surfaces 10 and 12 are flushed to the vertical surface of a wall when hanger 1 is attached to the wall
The first bend 3 is about a ¾ circular, frontward and upward bend that connects the lower end of first leg 2 and the lower end of second leg 4 in inclined position. The first leg 2 , first bend 3 and second leg 4 form an U-hook that becomes a hook section of the hanger 1 .
The second bend 5 is about a ½ circular, downward and rearward bend that connects the upper end of second leg 4 and the upper end of the third leg 6 in inclined position. The third bend 7 is a metric bend that connects the lower end of third leg 6 and the upper end of the fourth leg 8 in vertical position. A first and second through holes 13 and 14 are provided in the bending areas of second and third bends 5 and 7 respectively. The first hole 13 is about a circular hole with a diameter slightly greater than a nail 15 . The second hole 14 is a slot hole extending in the longitudinal direction from the lower end of third leg 6 to the upper end of fourth leg 8 . The nail 15 penetrates hanger 1 though first and second holes 13 and 14 , and enters into the wall in inclined position. The second bend 5 , third leg 6 , third bend 7 and fourth leg 8 form an anchor section of hanger 1 that anchors nail 15 into the wall. Alternatively, redundant first and second through holes 13 and 14 can be provided in the bending areas of second and third bends 5 and 7 respectively. (Not shown in FIG. 2A and FIG. 2B ) This allows redundant nail to drive through hanger 1 in parallel to nail 15 so that the loading capacity of hanger 1 can be increased.
As shown in FIG. 2A and FIG. 2B , there is a small gap between the lower end of second leg 4 and the lower end of third leg 6 . This gap is smaller than the diameter of nail 15 so that nail 15 can only penetrate the gap area through the second hole 14 . Alternatively, such a gap can be eliminated to allow the lower end of second leg 4 in the area of first bend 3 making contact with the lower end of third leg 6 in the area of third bend 7 .
According to the first preferred embodiments of present invention, the anchor section of hanger 1 including nail 15 is positioned below the hook section of hanger 1 . This allows a hanging wire to immediately engage into the hook section of hanger 1 without interference when the hanging wire approaches to hanger 1 from the top of hanger 1 . Preferably, the nail 15 drives through hanger 1 and into the wall at an angle between 45 degree and 60 degree departing from a horizontal plan. This not only maximizes the loading capacity of hanger 1 , but also prevents hanger 1 from swiveling or pivoting, and prevents nail 15 from slipping out of the wall. The hook and anchor sections of hanger 1 are integrated in such way that hanger 1 can be fabricated from continuously bending of a metal strip.
FIG. 3A and FIG. 3B show an alternative form of FIG. 2A and FIG. 2B respectively. Such an alternative form incorporates a change that relocates the second hole 14 from the area of third bend 7 to the area of first bend 3 .
FIG. 4A and FIG. 4B show the second preferred embodiments of the picture frame hanger of the invention. The hanger 16 comprises of a first vertical leg 17 , a first bend 18 , a second inclined leg 19 , a second bend 20 , a third leg 21 , a third bend 22 , a fourth leg 23 , a fourth bend 24 , a fifth leg 25 , a fifth bend 26 and a sixth vertical leg 27 . The first vertical leg 17 has a frontward vertical surface 28 and a rearward vertical surface 29 . The sixth vertical leg 27 has a frontward vertical surface 30 and a rearward vertical surface 31 . The rearward vertical surfaces 29 and 31 are flushed to the vertical surface of the wall when hanger 16 is attached to the wall.
The first bend 18 is about a ¾ circular, frontward and upward bend that connects the lower end of first leg 17 and the lower end of second leg 19 in inclined position. The first leg 17 , first bend 18 and second leg 19 form an U-hook that becomes a hook section of the hanger 16 .
The second bend 20 is about a 90 degree metric and frontward bend that connects the upper end of second leg 19 and the rearward end of the third leg 21 . The third bend 22 is about a 90 degree metric and downward bend that connects the frontward end of third leg 21 and the upper end of the fourth leg 23 in inclined position. The fourth bend 24 is an upward bend that connects the lower end of fourth leg 23 and the frontward end of the fifth leg 25 . The fifth bend 26 is a downward bend that connects the rearward end of fifth leg 25 and the upper end of sixth leg 27 in vertical position.
A first circular hole 32 is provided in mid section of third leg 21 . A second slot hole 33 is provided in the area of fifth bend 26 that extends in the longitudinal direction from the rearward end of fifth leg 25 and the upper end of sixth leg 27 . A nail 34 drives through first and second holes 32 and 33 before entering into the wall. The third, fourth, fifth and sixth legs and bends 21 through 27 form an anchor section of the hanger 16 . Alternatively, redundant first and second through holes 32 and 33 can be provided in the third leg 21 and the bending area of fifth bend 26 respectively. (Not shown in FIG. 4A and FIG. 4B ) This allows redundant nail to drive through hanger 16 in parallel to nail 34 so that the loading capacity of hanger 16 can be increased.
As shown in FIG. 4A and FIG. 4B , the lower end of second leg 19 makes contact with the rearward end of fifth leg 25 in the areas of first and fifth bends 18 and 26 . Alternatively, the lower end of second leg 19 does not make contact with the rearward end of fifth leg 25 in the areas of first and fifth bends 18 and 26 . This provides a small gap between the lower end of second leg 19 and the rearward end of fifth leg 25 in the areas of first and fifth bends 18 and 26 . Such a gap must be smaller than the diameter of nail 34 so that nail 34 can only penetrate the gap area through the second hole 33 .
According to the second preferred embodiments of present invention, the anchor section of hanger 16 including nail 34 is positioned below the hook section of hanger 16 . This allows a hanging wire to immediately engage into the hook section of hanger 16 without interference when the hanging wire approaches to hanger 16 from the top of hanger 16 . Preferably, the nail 34 drives through hanger 16 and into the wall at an angle between 45 degree and 60 degree departing from a horizontal plan. This not only mazes the loading capacity of hanger 16 , but also prevents hanger 16 from swiveling or pivoting, and prevents nail 34 from slipping out of the wall The hook and anchor sections of hanger 16 are integrated in such way that hanger 16 can be fabricated from continuously bending of a metal strip.
FIG. 5A and FIG. 5B show the third preferred embodiments of the picture frame hanger of the invention. The hanger 35 comprises of a first vertical leg 36 , a first bend 37 , a second inclined leg 38 , a second bend 39 , a third leg 40 , a third bend 41 , a fourth leg 42 , a fourth bend 43 and a fifth vertical leg 44 . The first vertical leg 36 has a frontward vertical surface 45 and a rearward vertical surface 46 . The fifth vertical leg 44 has a frontward vertical surface 47 and a rearward vertical surface 48 . The rearward vertical surfaces 46 and 48 are flushed to the vertical surface of the wall when hanger 35 is attached to the wall.
The first bend 37 is about a ¾ circular, frontward and upward bend that connects the lower end of first leg 36 and the lower end of second leg 38 in inclined position. The first leg 36 , first bend 37 and second leg 38 form an U-hook that becomes a hook section of the hanger 35 .
The second bend 39 is about a 90 degree metric and frontward bend that connects the upper end of second leg 38 and the rearward end of the third leg 40 . The third bend 41 is about a 90 degree metric and downward bend that connects the frontward end of third leg 40 and the upper end of the fourth leg 42 in inclined position. The fourth bend 43 is a downward bend that connects the lower end of fourth leg 42 and the upper end of the fifth leg 44 .
A first circular hole 49 is provided in mid section of third leg 40 . A second slot hole 50 is provided in the area of first bend 37 that extends in the longitudinal direction from the lower end of second leg 38 to the lower end of first leg 36 . A nail 51 drives through first and second holes 49 and 50 before entering into the wall The second, third, fourth, and fifth legs and bends 39 through 44 form an anchor section of the hanger 35 . Alternatively, redundant first and second through holes 49 and 50 can be provided in the third leg 40 and the bending area of first bend 37 respectively. (Not shown in FIG. 5A and FIG. 5B ) This allows redundant nail to drive through hanger 35 in parallel to nail 51 so that the loading capacity of hanger 35 can be increased.
As shown in FIG. 5A and FIG. 5B , the lower end of second leg 38 makes contact with the lower end of fourth leg 42 in the areas of first and fourth bends 37 and 43 . Alternatively, the lower end of second leg 38 does not make contact with the lower end of fourth leg 42 in the areas of first and fourth bends 37 and 43 . This provides a small gap between the lower end of second leg 38 and the lower end of fourth leg 42 in the areas of first and fourth bends 37 and 43 . Such a gap must be smaller than the diameter of nail 51 so that nail 51 can only penetrate the gap area through the second hole 50 .
According to the third preferred embodiments of present invention, the anchor section of hanger 35 including nail 51 is positioned below the hook section of hanger 35 . This allows a hanging wire to immediately engage into the hook section of hanger 35 without interference when the hanging wire approaches to hanger 35 from the top of hanger 35 . Preferably, the nail 51 drives through hanger 35 and into the wall at an angle between 45 degree and 60 degree departing from a horizontal plan. This not only mazes the loading capacity of hanger 35 , but also prevents hanger 35 from swiveling or pivoting, and prevents nail 51 from slipping out of the wall. The hook and anchor sections of hanger 35 are integrated in such way that hanger 35 can be fabricated from continuously bending of a metal strip.
FIG. 6A and FIG. 6B show the fourth preferred embodiments of the picture frame hanger of the invention. The hanger 52 comprises of a first vertical leg 53 , a first bend 54 , a second inclined leg 55 , a second bend 56 , a third leg 57 , a third bend 58 , a fourth leg 59 , a fourth bend 60 and a fifth vertical leg 61 . The first vertical leg 53 has a frontward vertical surface 62 and a rearward vertical surface 63 . The fifth vertical leg 61 has a frontward vertical surface 64 and a rearward vertical surface 65 . The rearward vertical surfaces 63 and 65 are flushed to the vertical surface of the wall when hanger 52 is attached to the wall.
The first bend 54 is about ¾ circular, frontward and upward bend that connects the lower end of first leg 53 and the lower end of second leg 55 in inclined position. The first leg 53 , first bend 54 and second leg 55 form an U-hook that becomes a hook section of the hanger 52 .
The second bend 56 is about a 90 degree metric and downward bend that connects the upper end of second leg 55 and the rearward end of the third leg 57 . The third bend 58 is about a 90 degree metric and downward bend that connects the frontward end of third leg 57 and the upper end of the fourth leg 59 in inclined position. The fourth bend 60 is an upward bend that connects the lower end of fourth leg 59 and the lower end of the fifth leg 61 . The upper end of fifth leg 61 is provided with a projectile 66 in frontward direction that makes contact with the bottom of the first bend 54 .
A first circular hole 67 is provided in mid section of third leg 57 . A second circular hole 68 is provided in mid section of fifth leg 61 . A nail 69 drives through first and second holes 67 and 68 before entering into the wall. The second, third, fourth and fifth legs and bends 56 through 61 form an anchor section of the hanger 52 . Alternatively, redundant first and second through holes 67 and 68 can be provided in the third leg 57 and the fifth leg 61 respectively. (Not shown in FIG. 6A and FIG. 6B ) This allows redundant nail to drive through hanger 52 in parallel to nail 69 so that the loading capacity of hanger 52 can be increased.
According to the fourth preferred embodiments of present invention, the anchor section of hanger 52 including nail 69 is positioned below the hook section of hanger 52 . This allows a hanging wire to immediately engage into the hook section of hanger 52 without interference when the hanging wire approaches to hanger 52 from the top of hanger 52 . Preferably, the nail 69 drives through hanger 52 and into the wall at an angle between 45 degree and 60 degree departing from a horizontal plan. This not only maximizes the loading capacity of hanger 52 , but also prevents hanger 52 from swiveling or pivoting, and prevents nail 69 from slipping out of the wall. The hook and anchor sections of hanger 52 are integrated in such way that hanger 52 can be fabricated from continuously bending of a metal strip.
FIG. 7A and FIG. 7B show the fifth preferred embodiments of the picture frame hanger of the invention. The fifth preferred embodiments are the alternative form of the second preferred embodiments shown in FIG. 4A and FIG. 4B . The fifth preferred embodiments are identical to the second preferred embodiments with one exception. In FIG. 4A and FIG. 4B , the first circular hole 32 is provided in mid section of the third leg 21 , and the second slot hole 33 is provided in the area of fifth bend 26 . However, in FIG. 7A and FIG. 7B , the first circular hole 70 is provided in mid section of third leg 71 , the second and third circular holes 72 and 73 are provided in mid section of fifth and sixth legs 74 and 75 respectively. Nail 76 drives through first, second and third circular holes 70 , 72 and 73 before entering into the wall.
FIG. 8A and FIG. 8B show the sixth preferred embodiments of the picture frame hanger of the invention. The hanger 77 comprises of a first vertical leg 78 , a first bend 79 , a second inclined leg 80 , a second bend 81 , a third leg 82 , a third bend 83 , a fourth leg 84 , a fourth bend 85 and a fifth leg 86 . The first vertical leg 78 has a frontward vertical surface 87 and a rearward vertical surface 88 . The rearward vertical surface 88 is flushed to the vertical surface of the wall when hanger 77 is attached to the wall
The first bend 79 is a frontward and upward bend that connects the lower end of first leg 78 and the lower end of second leg 80 in inclined position. The second bend 81 is about a 90 degree rearward bend that connects the upper end of second leg 80 and the frontward end of the third leg 82 . The third bend 83 is about a 90 degree downward bend that connects the rearward end of third leg 82 and the upper end of the fourth leg 84 . The fourth bend 85 is about a 90 degree downward bend that connects lower end of fourth leg 84 and the upper end of the fifth leg 86 . The fourth bend 85 makes contact with the frontward vertical surface 87 of first leg 78 in mid section of first leg 78 . The fourth bend 85 also positions fifth leg 86 in perpendicular to second leg 80 . The lower end of the fifth leg 86 makes contact with second leg 80 . This arrangement keeps fourth bend 85 in close contact with the frontward vertical surface 87 of the first leg 78 when the fourth bend 85 is subject to weight. This is necessary because the upper part of first leg 78 , fourth bend 85 and fourth leg 84 form an U-hook, and become the hook section of hanger 77 .
A first, second and third circular holes 89 , 90 and 91 are provided in mid sections of third, fifth and first legs 82 , 86 and 78 respectively. A nail 92 drives through first, second and third holes 89 , 90 and 91 before entering into the wall. Alternatively, redundant first, second and third through holes 89 , 90 and 91 can be provided in the third, fifth and first legs 82 , 86 and 78 respectively. (Not shown in FIG. 8A and FIG. 8B ) This allows redundant nail to drive through hanger 77 in parallel to nail 92 so that the loading capacity of hanger 77 can be increased.
According to the sixth preferred embodiments of present invention, the anchor section of hanger 77 including nail 92 is positioned below the hook section of hanger 77 . This allows a hanging wire to immediately engage into the hook section of hanger 77 without interference when the hanging wire approaches to hanger 77 from the top of hanger 77 . Preferably, the nail 92 drives through hanger 77 and into the wall at an angle between 45 degree and 60 degree departing from a horizontal plan This not only maximizes the loading capacity of hanger 77 , but also prevents hanger 77 from swiveling or pivoting, and prevents nail 92 from slipping out of the wall. The hook and anchor sections of hanger 77 are integrated in such way that hanger 77 can be fabricated from continuously bending of a metal strip.
FIG. 9A and FIG. 9B show the seventh preferred embodiments of the picture frame hanger of the invention. The seventh preferred embodiments are the alternative form of the sixth preferred embodiments shown in FIG. 8A and FIG. 8B . The seventh preferred embodiments are identical to the sixth preferred embodiments with one exception. In FIG. 8A and 8B , the fourth bend 85 is about a 90 degree bend that positions fifth leg 86 in perpendicular to second leg 80 . In FIG. 9A and FIG. 9B , the fourth bend 93 is greater than 90 degree that positions the fifth leg 94 in parallel to and in contact with the lower part of first leg 95 . The lower end of fifth leg 94 makes contact with first bend 96 . This arrangement keeps fourth bend 93 in close contact with first leg 95 when fourth bend 93 is subject to weight.
It is understood that innumerable variations, modifications, applications, and extensions of the principles hereinbefore set forth can be made without departing from the spirit and the scope of the invention.
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The hanger of present invention comprises of an integral hook and anchor sections in the upper and lower parts of hanger respectively. The hook section forms an U-hook for suspending and retaining the hanging wire of a picture frame. The anchor section guides a fastener such as a nail to drive through the anchor section and into the wall in inclined position. The hanger of present invention allows the hanging wire of the picture frame to directly engage into the U-hook without interference when a person holds the picture frame against the wall, and slides the picture frame downward to approach the hanger from the top of hanger.
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CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
This application is a Continuation of U.S. application Ser. No. 14/014,104, filed Aug. 29, 2013, which is a Continuation of U.S. application Ser. No. 13/470,972, filed May 14, 2012, now U.S. Pat. No. 8,552,758, which is a Continuation of U.S. application Ser. No. 12/876,760, filed Sep. 7, 2010, now U.S. Pat. No. 8,253,436, which claims the benefit of Japanese Patent Application No. 2009-206880, filed Sep. 8, 2009, incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a semiconductor integrated circuit, and more particularly, to a semiconductor integrated circuit suitable for power-supply noise reduction.
2. Description of Related Art
In a semiconductor integrated circuit, there has been a problem that data transmission between a data transmitting circuit and a data receiving circuit is not accurately executed when power-supply noise occurs on signal lines used for the data transmission between these circuits.
Therefore, a countermeasure, for example, ODT (On Die Termination) technique has been provided to reduce the power-supply noise on signal lines used for data reception of the data receiving circuit (JEDEC STANDARD, DDR2 SDRAM SPECIFICATION JESD79-2E (Revision of JESD79-2D), April 2008, JEDEC SOLID STATE TECHNOLOGY ASSOCIATION).
SUMMARY OF THE INVENTION
In the related art, the countermeasure such as an ODT function has been provided to reduce the power-supply noise which influences the data receiving circuit. However, the related art provides no countermeasure to reduce the power-supply noise which influences the data transmitting circuit. Normally, the data transmitting circuit includes a data output circuit such as a three-state buffer for transmitting data. The data transmitting circuit controls whether the data output circuit outputs the data or not based on a control signal. In other words, the data transmitting circuit controls the data output circuit to output the data or to switch the output of the data output circuit to a high impedance state (HiZ).
However, in the related art, the power-supply noise occurs when the data transmitting circuit controls the output of the data output circuit to be set to HiZ, because the supply of power supply voltage to the signal lines to which the power supply voltage has continuously been supplied is suddenly interrupted. When the data transmitting circuit switches the output of the data output circuit from HiZ to a data transmission state so as to output another data before the power-supply noise converges, another data is influenced by the power-supply noise. The present inventors have found a problem in the related art that, as described above, it is impossible for the data transmitting circuit to transmit the data accurately.
An exemplary aspect of the present invention is a semiconductor integrated circuit including:
a data transmitting circuit; and
a data receiving circuit that receives data transmitted from the data transmitting circuit, in which
the data transmitting circuit includes:
a data output circuit that outputs the data or sets an output to a high impedance state; and a control circuit that outputs a control signal to the data output circuit so that the data output circuit outputs the data when the data transmitting circuit transmits the data, and the data output circuit keeps outputting data last output in the previous data transmission, during a predetermined period after the previous data transmission when the data transmitting circuit further transmits another data after transmitting the data.
With the circuit structure as described above, it is possible to transmit data accurately by reducing the power-supply noise.
According to an exemplary aspect of the present invention, it is possible to provide a semiconductor integrated circuit capable of transmitting data accurately.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other exemplary aspects, advantages and features will be more apparent from the following description of certain exemplary embodiments taken in conjunction with the accompanying drawings, in which:
FIG. 1 illustrates a semiconductor integrated circuit according to a first exemplary embodiment of the present invention;
FIG. 2 illustrates the semiconductor integrated circuit according to the first exemplary embodiment of the present invention; and
FIG. 3 is a timing chart depicting an operation of the semiconductor integrated circuit according to the first exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Specific exemplary embodiments of the present invention are described in detail below with reference to the drawings. The same components are denoted by the same reference numerals in the drawings, and for clarity of explanation, repeated explanation is omitted as appropriate.
[First Exemplary Embodiment]
Referring to the drawings, a semiconductor integrated circuit according to a first exemplary embodiment of the present invention will be described. The present invention can be applied to a circuit which includes a data transmitting circuit and a data receiving circuit that receives data transmitted from the data transmitting circuit, and which controls the output of the data transmitting circuit based on a control signal. In this exemplary embodiment, a case is explained hereinafter in which the circuit shown in FIG. 1 includes an SoC (System on Chip) circuit and an SDRAM (Synchronous Dynamic Random Access Memory) circuit, and data transmission is executed between the SoC circuit and the SDRAM circuit through a signal line for bidirectionally transmitting data between these circuits (hereinafter, referred to simply as “bidirectional signal line”).
FIG. 1 illustrates a semiconductor integrated circuit according to the first exemplary embodiment of the present invention. The circuit shown in FIG. 1 includes an SoC circuit (data transmitting circuit) 100 and an SDRAM circuit (data receiving circuit) 101 . Data transmission is executed between the SoC circuit 100 and the SDRAM circuit 101 in the DDR (double data rate) mode.
First, the circuit structure of the semiconductor integrated circuit according to the first exemplary embodiment of the present invention will be described. The SoC circuit 100 outputs a 2-bit clock signal CK and a 2-bit clock signal CKB, which is a differential signal of the clock signal CK, to the SDRAM circuit 101 . The SoC circuit 100 further outputs a 16-bit control signal CMD, which includes commands for each address of the SDRAM circuit 101 , to the SDRAM circuit 101 . Note that the SDRAM circuit 101 receives the control signal CMD in synchronization with the clock signals CK and CKB.
Each of 32-bit data DQ, a 4-bit strobe signal DQS, and a 4-bit strobe signal DQSB, which is a differential signal of the strobe signal DQS, is bidirectionally transmitted and received between the SoC circuit 100 and the SDRAM circuit 101 . A receiving circuit, which is one of the SoC circuit 100 and the SDRAM circuit 101 , receives the data DQ in synchronization with the strobe signals DQS and DQSB. Note that the signal names described above also represent the corresponding signal line names.
The circuit shown in FIG. 2 shows a 1-bit bidirectional signal line, which is one of strobe signal lines DQS[ 3 : 0 ] and DQSB[ 3 : 0 ] and a data signal line DQ[ 31 : 0 ], and corresponding peripheral circuits of the circuit shown in FIG. 1 . In this exemplary embodiment, a case is explained hereinafter in which the 1-bit bidirectional signal line is the data signal line DQ[ 0 ]. The data signal line DQ[ 0 ] is connected between the SoC circuit 100 and the SDRAM 101 as described above.
The SoC circuit 100 includes an external terminal 201 , a buffer 202 , a data output circuit 203 which outputs data, a termination circuit 204 which has an ODT function, a control circuit 205 which outputs control signals to each of the data output circuit 203 and the termination circuit 204 , and an inverter 206 . The termination circuit 204 includes a resistor 207 , a resistor 208 , a switch 209 , and a switch 210 . The data output circuit 203 includes a NAND circuit 251 , a NOR circuit 252 , a transistor 253 , and a transistor 254 . In this exemplary embodiment, a case is explained in which the switch 209 and the transistor 253 are P-channel MOS transistors and the switch 210 and the transistor 254 are N-channel MOS transistors.
In the SoC circuit 100 , the data signal line DQ[ 0 ] is connected to an input terminal of the buffer 202 and an output terminal of the data output circuit 203 through the external terminal 201 .
The termination circuit 204 is provided between the external terminal 201 and the buffer 202 . In the termination circuit 204 , the switch 209 and the resistor 207 are connected in series between a high potential side power supply terminal VDD and a node N 1 which is located on the signal line connecting the external terminal 201 and the buffer 202 . The switch 210 and the resistor 208 are connected in series between a low potential side power supply terminal VSS and the node N 1 . In other words, the source terminal of the switch 209 is connected to the high potential side power supply terminal VDD. The drain terminal of the switch 209 is connected to one terminal of the resistor 207 . The other terminal of the resistor 207 is connected to one terminal of the resistor 208 . The other terminal of the resistor 208 is connected to the drain terminal of the switch 210 . The source terminal of the switch 210 is connected to the low potential side power supply terminal VSS. The other terminal of the resistor 207 and one terminal of the resistor 208 are commonly connected to the node NI. Note that the switch 209 and the resistor 207 which are connected in series between the high potential side power supply terminal VDD and the node N 1 may be switched around. Similarly, the switch 210 and the resistor 208 which are connected in series between the low potential side power supply terminal VSS and the node N 1 may be switched around.
An output terminal of the buffer 202 is connected to an input terminal IN used for inputting data of the control circuit 205 . An output terminal C 1 of the control circuit 205 is connected to the gate terminal of the switch 209 and the gate terminal of the switch 210 through the inverter 206 . Such a peripheral circuit configuration is also employed in the other bidirectional signal lines. Note that the control circuit 205 is commonly provided to these bidirectional signal lines.
An output terminal OUT used for outputting data of the control circuit 205 is connected to one input terminal of the NAND circuit 251 and one input terminal of the NOR circuit 252 in the data output circuit 203 . An output terminal E 1 for outputting a control signal 230 of the control circuit 205 is connected to the other input terminal of the NAND circuit 251 and the other input terminal of the NOR circuit 252 through the inverter 255 in the data output circuit 203 . An output terminal of the NAND circuit 251 is connected to the gate terminal of the transistor 253 . An output terminal of the NOR circuit 252 is connected to the gate terminal of the transistor 254 . The transistors 253 and 254 are connected in series between the high potential side power supply terminal VDD and the low potential side power supply terminal VSS. In other words, the transistors 253 and 254 constitute an inverter. The drain terminal of the transistor 253 and the drain terminal of the transistor 254 are commonly connected to a node which is located on the signal line connecting between the buffer 202 and the external terminal 201 . Such a peripheral circuit configuration is also employed in the other bidirectional signal lines.
Next, the operation of the semiconductor integrated circuit according to the first exemplary embodiment of the present invention will be described. A case is explained hereinafter in which the SoC circuit 100 receives (reads) the data such as the data DQ transmitted from the SDRAM circuit 101 . First, the SoC circuit 100 outputs the control signal CMD to the SDRAM circuit 101 . After that, for example, the SDRAM circuit 101 transmits the data DQ stored in a memory area of an address specified by the control signal CMD, and the strobe signals DQS and DQSB to the SoC circuit 100 . In this case, the data DQ transmitted from the SDRAM circuit 101 has a predetermined burst length.
The SoC circuit 100 receives each signal output from the SDRAM circuit 101 through the corresponding signal line, external terminal 201 , and buffer 202 . Note that the SoC circuit 100 receives the data DQ in synchronization with the strobe signals DQS and DQSB. The data DQ received by the SoC circuit 100 is input to the control circuit 205 and the other peripheral circuits (not shown). A period between the time when the SoC circuit 100 starts to transmit the control signal CMD and the time when the SoC circuit 100 starts to receive the corresponding data DQ is called a read latency (RL).
When receiving the data transmitted from the SDRAM circuit 101 , the SoC circuit 100 controls the ODT function of the corresponding termination circuit 204 to be turned on to reduce power-supply noise occurring on the data signal line DQ and the strobe signal lines DQS and DQSB. Specifically, the SoC circuit 100 controls the switches 209 and 210 , which are provided in the corresponding termination circuit 204 , to be turned on based on a control signal 200 from the control circuit 205 and sets the node on the corresponding signal line to a predetermined potential (for example, one-half of the high potential side power supply voltage VDD). This makes it possible for the SoC circuit 100 to receive the data accurately by reducing the power-supply noise included in the received data.
Moreover, the SoC circuit 100 controls the data output circuit 203 not to output the data to the SDRAM circuit 101 based on the control signal 230 from the control circuit 205 . In other words, the SoC circuit 100 controls the output of the data output circuit 203 to be set to a high impedance state (HiZ) based on the control signal 230 of L level. The output of the data output circuit 203 indicates HiZ because the transistors 253 and 254 are both controlled to be turned off when the control signal 230 is L level. This makes it possible for the SoC circuit 100 to accurately receive the data transmitted from the SDRAM circuit 101 without being influenced by the other data output from the data output circuit 203 .
A case is explained hereinafter in which the SoC circuit 100 transmits (writes) the data to the SDRAM circuit 101 . First, the SoC circuit 100 outputs the control signal CMD to the SDRAM circuit 101 . After that, the SoC circuit 100 transmits the data DQ and the strobe signals DQS and DQSB to the SDRAM circuit 101 . In this case, the data DQ transmitted from the SoC circuit 100 has a predetermined burst length.
Then, the SDRAM circuit 101 receives the data DQ in synchronization with the strobe signals DQS and DQSB. For example, the data DQ is written into the memory area of the address specified by the control signal CMD. A period between the time when the SoC circuit 100 starts to transmit the control signal CMD and the time when the SoC circuit 100 starts to transmit the corresponding data DQ is called a write latency (WL).
When transmitting the data to the SDRAM circuit 101 , the SoC circuit 100 controls the ODT function of the corresponding termination circuit 204 to be turned off. Specifically, the SoC circuit 100 controls the switches 209 and 210 , which are provided in the corresponding termination circuit 204 , to be turned off based on the control signal 200 from the control circuit 205 , thereby preventing the potential of the data transmitted to the SDRAM circuit 101 through the data output circuit 203 and the external terminal 201 from being decayed. This makes it possible for the SoC circuit 100 to transmit the data accurately.
The SoC circuit 100 controls the data output circuit 203 to output the data to the SDRAM circuit 101 based on the control signal 230 from the control circuit 205 . In other words, the SoC circuit 100 controls the data output circuit 203 to output the data to the SDRAM circuit 101 based on the control signal 230 of H level. When the control signal 230 is H level, the transistors 253 and 254 are controlled to be turned on and off in accordance with the data output from the control circuit 205 . Thereby, the SoC circuit 100 transmits the data to the SDRAM circuit 101 .
In this manner, the SoC circuit 100 switches between a read mode in which the SoC circuit 100 receives the data transmitted from the SDRAM circuit 101 and a write mode in which the SoC circuit 100 transmits the data to the SDRAM circuit 101 , based on the control signal CMD. Note that the SoC circuit 100 outputs the control signal CMD which has a data length corresponding to one cycle of the clock signal CK at predetermined time intervals.
For example, the SoC circuit 100 receives data such as the data DQ in the read mode or transmits the data in the write mode, and after the predetermined time interval, receives or transmits another data in the same mode. Alternatively, the SoC circuit 100 receives data such as the data DQ in the read mode or transmits the data in the write mode, and after the predetermined time interval, receives or transmits another data in a different mode. The data transmission and reception as described above is repeated.
The SoC circuit 100 according to this exemplary embodiment exhibits characteristics when the SoC circuit 100 transmits data such as the data DQ in the write mode, and after the predetermined time interval, transmits another data in the write mode again. The operation of the SoC circuit 100 in this case will be described with reference to FIG. 3 .
First, the SoC circuit 100 outputs the control signal CMD (which is indicated by “A” shown in FIG. 3 and is hereinafter referred to as “write command A”) to the SDRAM circuit 101 . Then, the SoC circuit 100 transmits the data DQ (“D” shown in FIG. 3 ), which has a predetermined burst length, and the corresponding strobe signals DQS and DQSB to the SDRAM circuit 101 after the period of the write latency WL (“C” shown in FIG. 3 ).
In this case, when transmitting the data, the SoC circuit 100 controls the corresponding data output circuit 203 to output the data.
After outputting the write command A, the SoC circuit 100 outputs a write command E (“E” shown in FIG. 3 ) after the period of the predetermined time interval (“B” shown in FIG. 3 ). Then, the SoC circuit 100 transmits the data DQ (“G” shown in FIG. 3 ), which has a predetermined burst length, and the corresponding strobe signals DQS and DQSB to the SDRAM circuit 101 after the period of the write latency WL (“F” shown in FIG. 3 ).
In this case, the control circuit 205 calculates a period (H), in which the data DQ is not transmitted, based on the interval (B) of the write commands (A, E), the write latency WL (C, F), and the burst length (D, G) of the data DQ. Based on the period thus obtained, the control circuit 205 determines whether the data output circuit 203 outputs the data or not during the period (H) in which the data DQ is not transmitted. Then, the control circuit 205 outputs the control signal 230 to the data output circuit 203 based on the results of the determination.
When the period (H) is less than or equal to a predetermined threshold, the data output circuit 203 keeps outputting the last data (data “03” shown in FIG. 3 ) of the data DQ (D) during the period (H). When the period (H) exceeds the predetermined threshold, the data output circuit 203 switches the output to HiZ during the period (H).
In the case where the write mode is repeated, when the data output circuit 203 keeps outputting the last data during the period (for example, “H” shown in FIG. 3 ) in which the data transmission is not executed, power-supply noise, which may occur due to switching of the output to HiZ by the data output circuit 203 , does not occur on the signal line at the output side of to the data output circuit 203 . Therefore, it is possible for the SoC circuit 100 to transmit the data accurately by reducing the power-supply noise which has been a problem in the related art.
In the case where the write mode is repeated, when the period (for example, “H” shown in FIG. 3 ) in which the data transmission is not executed exceeds the threshold, the data output circuit 203 switches the output to HiZ during the period in which the data transmission is not executed. In this case, the power-supply noise on the corresponding signal line caused by switching the output state of the data output circuit 203 converges because the period in which the data transmission is not executed is sufficiently long. In other words, the SoC circuit 100 can transmit another data output from the data output circuit 203 without being influenced by the power-supply noise. This makes it possible for the SoC circuit 100 to transmit the data accurately by reducing the effect of the power-supply noise. Note that the timing of switching the output of the data output circuit 203 to HiZ may be arbitrarily determined as long as the power-supply noise is converged by the time when the next data transmission starts.
As described above, in the case where the data transmitting circuit (for example, the SoC circuit 100 ) continuously transmits the data, the semiconductor integrated circuit according to this exemplary embodiment controls the output of the data output circuit (for example, the data output circuit 203 ) included in the data transmitting circuit based on a data transmission interval. In other words, the semiconductor integrated circuit according to this exemplary embodiment controls the data output circuit continuously to output the data or to switch the output to HiZ. This makes it possible for the semiconductor integrated circuit according to this exemplary embodiment to transmit the data accurately by reducing the effect of the power-supply noise.
Note that the present invention is not limited to the above exemplary embodiments, but can be modified as appropriate within the scope of the present invention. For example, though the above-mentioned exemplary embodiments have described an example in which the SoC circuit 100 transmits the data to the SDRAM circuit 101 , the present invention is not limited thereto. The present invention is also applicable to a circuit configuration in which the SDRAM circuit 101 transmits the data to the SoC circuit 100 . In this case, the data output circuit included in the SDRAM circuit 101 must be controlled as in the case of the data output circuit 203 included in the SoC circuit 100 .
Though the above-mentioned exemplary embodiments have described an example in which, when the data transmitting circuit (for example, the SoC circuit 100 ) continuously transmits data, the control circuit 205 outputs the control signal (for example, the control signal 230 ) based on the interval of the address command such as a write command, the write latency WL, and the burst length of the data DQ, the present invention is not limited thereto. The present invention is also applicable to a circuit configuration for outputting the control signal (for example, the control signal 230 ) based on at least one of the above-mentioned pieces of information (for example, the interval of the address command) if it is possible to control the output of the data output circuit 203 based on the data transmission interval.
Though the above-mentioned exemplary embodiments have described the case where the signal line which is used for the output of the data output circuit 203 is a bidirectional signal line, the present invention is not limited thereto. The present invention is also applicable to a circuit configuration in which the signal line which is used for the output of the data output circuit 203 is a signal line dedicated for transmitting data.
The termination circuit is not limited to the circuits illustrated in the above-mentioned exemplary embodiments. The present invention is also applicable to a circuit configuration including a resistor and a switch which are connected in series between the power supply terminal having the predetermined potential (for example, one-half of the high potential side power supply voltage VDD) and the node on the corresponding signal line. Moreover, though the above-mentioned exemplary embodiments have described the case where the termination circuit is included, the present invention is not limited thereto. The present invention is also applicable to a circuit configuration in which the termination circuit is not included.
Though the above-mentioned exemplary embodiments have described an example in which the semiconductor integrated circuit includes a single SDRAM circuit, the present invention is not limited thereto. The semiconductor integrated circuit according to the present invention is also applicable to a circuit configuration including a plurality of SDRAM circuits.
While the invention has been described in terms of several exemplary embodiments, those skilled in the art will recognize that the invention can be practiced with various modifications within the spirit and scope of the appended claims and the invention is not limited to the examples described above.
Further, the scope of the claims is not limited by the exemplary embodiments described above.
Furthermore, it is noted that, Applicants' intent is to encompass equivalents of all claim elements, even if amended later during prosecution.
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A data transmitting method used in a semiconductor device having a controller and a transmitter is described. A first write command is output by the controller and then a second write command is output by the controller. An interval time between the first write command and the second write command is calculated. The transmitter is activated by the controller and a first data is transmitted by the transmitter in accordance with the first write command, and then the transmitter is inactivated based on the interval time. Then the transmitter is activated when the transmitter is inactivated. Then, the second data is transmitted by the transmitter in accordance with the second write command.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to a backrest for a driver of a motorcycle which will pivot forwardly for clearance for a passenger to mount a passenger's seat, and which has pivot assemblies that can be adjusted to different longitudinal positions in a fore and aft direction.
[0002] Backrests for motorcycle drivers have been utilized for increasing rider comfort. Some existing backrests permit adjusting the pivot mounting for the backrest in fore and aft direction along brackets on the sides of a motorcycle. However, the mounting is generally complex and requires tools for removing and replacing the pivot mounting. The typical prior art backrest is shown in U.S. Pat. No. 4,596,422.
SUMMARY OF THE INVENTION
[0003] The present invention relates to a pivotal mounting for a motorcycle driver backrest that has a pair of pivot support assemblies that can be reliably locked into position on support brackets on a motorcycle, but also quickly removed and/or repositioned longitudinally when desired.
[0004] The backrest engages a rearward mechanical stop in its usable position and it will pivot forwardly from its usable position to a second stopped position. The forward pivoting provides clearance for a passenger to mount the motorcycle.
[0005] The pivot support assemblies have a quick release lock that locks the pivot supports for the backrest onto the support brackets using an irregularly shaped opening that insures each pivot support is properly oriented when installed and which holds the pivot supports stationary when the backrest is pivoted. The loads on the backrest are carried adequately. The pivot support assemblies are held with a quick release arrangement so the pivot support assemblies can be quickly removed or changed in position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 fragmentarily shows a motorcycle with a backrest made according to the present invention installed thereon at the rear of the driver's seat;
[0007] FIG. 2 is an enlarged side view of the right hand pivot support assembly shown in FIG. 1 .
[0008] FIG. 3 is a perspective view of the inside of the left hand pivot support assembly for the backrest shown in FIG. 1 ;
[0009] FIG. 4 is an exploded view of FIG. 2 showing the parts used with the same pivot support shown in FIG. 2 ;
[0010] FIG. 5 is a view from an interior side of the left hand pivot support assembly of a motorcycle showing the mounting bracket used with the backrest of the present invention;
[0011] FIG. 6 is an enlarged sectional view taken along FIG. 6-6 in FIG. 4 ;
[0012] FIG. 7 is a fragmentary sectional view taken on line 7 - 7 in FIG. 5 ; and
[0013] FIG. 8 is a fragmentary sectional view taken on line 8 - 8 in FIG. 7 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0014] Referring to FIG. 1 , a motorcycle is shown fragmentarily at 10 , and is of a conventional design. It includes a frame mounting a rider's seat 12 adjacent handlebars 14 and it has a passenger seat 16 . A trunk is shown generally at 18 . The frame of the motorcycle or other structural members extend upwardly along to the inside of the side panels 20 of the trunk.
[0015] A driver's backrest mounting bracket 22 is secured to the panel 20 or to any suitable portion of the frame on each side of the motorcycle. A separate backrest mounting bracket 22 is mounted on each side of the motorcycle, and the mounting brackets 22 have forwardly projecting strap portions 24 onto which a backrest assembly 26 is mounted.
[0016] The backrest assembly 26 includes a pair of support struts 30 that each have a pivot support assembly 32 at the lower end. The struts 30 support a backrest pad 33 in a suitable manner. Referring to FIG. 5 , which is a view from the interior side of the left hand bracket strap 26 and pivot support assembly 32 , it can be seen that the forwardly extending strap 24 has three irregularly shaped, polygonal openings 26 A, 26 B, and 26 C formed therein. A separate pivot support assembly 32 supports each of the struts 30 . The brackets 22 are mounted on suitable structural elements of the motorcycle that have sufficient strength to support the backrest.
[0017] The pivot support assemblies 32 are supported on the brackets 22 and are releasably mounted for quick adjustment along (fore and aft), or removal from, the brackets.
[0018] Referring to FIGS. 3-6 in particular, each pivot support assembly 32 includes a strut support disc 35 that has a lower flattened end 30 A of the strut 30 on each side of the motorcycle. The flattened ends 30 A are fixed (welded) to the strut support disc 35 ( FIG. 6 ). The flattened ends 30 A have holes that fit over a hub 35 at the center of the respective strut support disc and the flattened end extends across the diameter of the strut support disc. A cover housing 34 has stand off lugs 37 and rivets or fasteners 37 A are used to fix the housing 34 to the respective strut support disc 35 .
[0019] The housing 34 on each side has an open neck 36 that receives the strut and a part annular flange 38 that extends around a central axis 41 of the support assembly 32 ( FIG. 4 ). A mounting pivot disc 42 , as shown in FIG. 6 , has a sleeve 46 that extends to one side and which pivotally supports the hub 35 B of strut support disc 35 so the struts 30 can pivot between the desired portions.
[0020] The pivot disc support lug 44 that is integral with the pivot disc 42 is formed on a side of the disc opposite from sleeve 46 . The lug 44 mounts the respective pivot disc 42 and the entire pivot support assembly 32 to the respective brackets 24 . A central bore 45 is formed in the sleeve 46 and the pivot disc 42 . The strut support discs 35 and housings 34 are thus pivotally mounted relative to the respective pivot disc 42 through the mounting of hub 35 B of disc 35 on sleeve 46 . The struts 30 pivot with the respective disc 35 on the respective sleeve 46 .
[0021] A detent disc or ring 48 is slid onto the exterior of each sleeve 46 at the outer end of the sleeve and held in place with a pair of adjustable jam nuts 47 A and 47 B that thread onto the exterior of sleeve 46 on opposite sides of the disc 48 . The detent disc or ring 48 is thus held relative to the sleeve 46 . The jam nuts 47 A and 47 B can be reliably secured in place. Thus, the detent ring remains in a fixed position relative to the pivot disc 42 . The strut support disc 35 and the flat end portion 30 A of the respective strut are urged toward the radial flange surface of the respective pivot disc 42 with a pair of Belleville washers 49 A and 49 B that are between jam nut 47 B and the pivot disc 35 . The ______ washers 49 A and 49 B mounted as shown and are spring loaded. Adjusting jam nut 47 B changes the spring load so a desired resistance to pivoting of the backrest can be provided. A low friction material disc 51 is between the flattened end 30 A of the strut and the radial flange side surface of pivot disc 42 .
[0022] The support lug 44 on the pivot disc 42 is of size and shape to extend through one of the openings 26 A, 26 B or 26 C of one of the brackets 22 , and the support lug 44 has an axially length substantially the same as, or slightly longer than, the thickness of the strap portion 24 of the respective mounting bracket 22 . A low friction material spacer 53 can be used to get the proper position of the outer end of lug 44 . The irregular (polygonal) shape of openings 26 A-C and the lug 44 are oriented so the pivot assemblies will always be at the proper rotational position when the lugs 44 are in place.
[0023] A latch cam or dog 50 is non-rotatably held on a central bolt or pin 52 that passes through the bore 45 in the pivot disc 42 , in sleeve 46 and support lug 44 . The latch dog 50 slidably rests on the outer end surface of lug 44 . The other end of the bolt or pin 52 is non-rotatably secured to a hand actuator disc 56 . The lock dog 50 is threaded onto the bolt or pin at the desired location that permits rotating the latch dog. The latch dog is held in place on the central bolt or pin 52 with a suitable lock nut 54 . The hand actuator disc 56 has a hub 58 that is rotatably guided for rotation within an opening 60 in the wall 39 ( FIGS. 2 and 6 ). The hub 58 has three pockets shown at 62 that have springs in the pockets 64 which spring load detent balls 66 in an axial direction to engage and releasably seat in openings 68 in the detent disc or ring 48 .
[0024] The strut support disc 35 supports the wall 39 of the housing 34 , as previously explained. The pivot disc 42 is secured to the bracket 22 and forms a stationary support. Each sleeve 46 rotatably supports the associated hub 35 B, the strut support disc 35 , the respective strut 30 and housing 34 when in a working assembly as shown in cross-section in FIG. 6 . The pivot disc 42 periphery fits within the flange 38 of the housing 34 .
[0025] The pivot discs 42 are mounted in the brackets 22 , on the sides of the motorcycle. The struts 30 , strut support discs 35 , and housings 34 will pivot about the axis 41 relative to the pivot discs 42 , and thus will pivot relative to the brackets 22 and the motorcycle.
[0026] It has been explained that the detent disc 48 is secured to the pivot disc 42 , so detent disc or ring 48 and the hand actuator disc remain with the disc 42 when the backrest is pivoted and do not pivot or rotate. The hand actuator disc 56 , which mounts to screw 52 and controls the rotational position of the lock dog or cam 50 , will remain in its position relative to the pivot disc 42 until the hand actuator disc is rotated with manual force to move from its detented position.
[0027] The pivot disc 42 has pre-shaped or wedge shaped fixed stop lugs 55 A and 55 B projecting from the side surface opposite from the support lug 44 . As can be seen in FIG. 7 , in one relative pivotal position of the struts 30 and the disc and housing, one edge of each of the flattened portions 30 A of the struts 30 will engage a respective first stop lug 55 A. FIG. 7 shows one of the struts 30 in its usable or working position with the strut extending generally uprightly. The struts 30 , support discs 35 , and the housing 34 can be rotated in direction as indicated by the arrow 57 , so that the second edges of the flattened portions 30 A of the struts 30 will engage a respective second stop lug 55 B that is shown in dotted lines in FIG. 7 as well. The struts 30 can pivot forwardly and lower the backrest down toward the driver's seat. The pivot amount permitted is about 90 degrees, between the stops, but the backrest may not have to be pivoted that much to provide passenger clearance. FIG. 8 shows the stop face of lug 55 A.
[0028] The pivot disc 42 is fixed relative to the brackets 22 so the stops 55 A and 55 B are also fixed relative to the motorcycle. The stops limit the pivoting movement of the rider backrest assembly.
[0029] The latch dog 50 is held securely on the pin or screw 52 so that it will rotate positively when the hand actuator disc 56 is rotated relative to the pivot disc 42 . The detent balls 66 will retract against the springs 64 so that the rotation of the latch dog 50 can take place for removal of the struts 30 from the brackets 22 . The hand actuator disc 56 will not rotate unintentionally.
[0030] The latch dog 50 will move between a solid line position shown in FIG. 4 where the lug 44 can be withdrawn from the opening 26 B and the pivot disc 42 , the housing 34 and the respective strut 30 can be removed from the bracket 22 , and either moved to a different opening in the strap portion 24 at each side of the motorcycle, or left off, if the backrest is not needed or desired.
[0031] When the latch dog 50 is moved by turning the hand actuator disc 56 substantially 60 degrees, the latch dog 50 moves to its dotted line position in FIG. 4 and will lock the hub 44 in the aperture on the strap 24 so that the pivot assembly cannot be removed from the bracket strap 24 . The locked position of the hand actuator disc is the detented positions, so the latch dog 50 will securely hold the struts and the backrest in place. The locked position of the hand actuator disc 56 is shown in FIG. 2 where an indicator arrow 70 on one of three raised ribs 72 aligns with a mark 74 on the housing 34 .
[0032] Struts 30 can be flexed outwardly far enough so that the respective support lug 44 and the latch dog 54 will clear the brackets 22 so that the backrest can be removed.
[0033] The latch dog 50 is operated by the hand actuator disc 56 for locking the pivot disc in position on the bracket mounted on the motorcycle. The latch dog 50 can be moved to a position where it will pass through the opening for the support lug 44 on the pivot disc. The backrest can be removed and replaced, or repositioned without special tools, and it can be done quickly, efficiently and positively. The backrest will remain locked in place in use because the detenting of the hand actuator disc 56 in its locked position.
[0034] When the backrest is pivoted forwardly, the hand actuator disc remains in its locking position, since the support disc 35 moves, but the pivot disc 42 detent ring 48 , the hand actuator disc 56 and the latch cam or dog 50 do not rotate and remain stationary.
[0035] Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.
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A motorcycle driver backrest has a pair of struts that support a backrest pad and are positioned on opposite sides of a motorcycle, where they are pivotally supported on brackets on the motorcycle. The struts have pivot assemblies that attach to the brackets that permit the backrest to be moved from a stopped working position for supporting a back of a motorcycle rider, to a forwardly folded position. The pivot assemblies are locked onto the brackets with latch dogs, and the latch dogs in turn are moveable between latched and unlatched positions with a hand actuator disc accessible from the exterior of the pivot assemblies. When the latch dog is in an unlatched position, the struts can be sprung apart for removal from the brackets.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a puzzle container which provides a surface for assembling the pieces of a jigsaw type puzzle and provides means for storing the puzzle pieces therein.
2. Discussion of Related Art
The puzzle containers of the prior art typically are directed to specific puzzles and apparatuses for their containment therein. These prior art puzzle apparatuses are designed for specific puzzles and do not provide a means for storing and assembling a variety of different sized puzzles. For example, U.S. Pat. No. 4,142,726 describes a laminated jigsaw puzzle in which the pieces of the puzzle are designed so that they can be bent for insertion under the ledge of a picture frame assembly.
There are prior art puzzle containers which disclose means for containing and securing the pieces of a puzzle. These prior art puzzle containers are complicated and not appropriate to varying puzzle thicknesses. In U.S. Pat. No. 4,687,202, a puzzle box is disclosed which has a top portion with sidewalls which are used to interengage the sidewalls of a bottom portion to secure the puzzle pieces between the top and bottom portions. In U.S. Pat. No. 4,154,339, a container is disclosed in which puzzle pieces are held in position with a lid. The lid comprises a hard top surface with a resilient pad underneath. The lid can be lodged using grommets within groves of the frame and the resilient pad underneath presses against the puzzle pieces which rest on a flat backing surface.
SUMMARY OF THE INVENTION
The present invention provides an assembly surface for jigsaw type puzzles and a simple mechanism for securing the puzzle pieces in place. The pieces are secured with a flexible cover which may be easily engaged and disengaged with the retainer frame of the puzzle to provide a simple and quick means of storing a completed puzzle or partially assembled puzzle.
The puzzle storage board of the present invention is comprised of a flexible cover, a retainer frame having a convex base for receiving said puzzle pieces, and a means for securing said flexible cover to said retainer frame for retaining said puzzle pieces.
The base of the puzzle storage board is convex in shape to minimize the tendency of the puzzle pieces to become displaced. The flexible cover when engaged with the retainer frame comes in contact with the convex base and puzzle pieces which have been placed on the convex base. The flexible cover together with the convex base provides a minimum uniform force on all areas of the puzzle surface for securing the puzzle pieces in place on the convex base.
The working surface provided by the convex base receives the components of a jigsaw puzzle, and when it is desired to transport or store the puzzle, the flexible cover is placed over the working surface to sandwich the pieces of the puzzle between the cover and the convex base. The flexible cover is inserted into a deep recess which is formed in one end of the retainer frame and is then depressed and slid into a relatively shallow recess at the opposite end of the retainer frame. Preferably the flexible cover is transparent for viewing. In a particular preferred embodiment, the flexible cover is plexiglass.
The present invention provides a portable working surface which can be used indoors, outdoors or in vehicles. Additionally, a puzzle can be displayed in the storage board for viewing. When the flexible cover is engaged with the retainer frame, the assembled and unassembled pieces of the puzzle are immobilized and confined regardless of the position in which the puzzle storage board is kept.
In its broad aspect, the puzzle storage board and container for pieces of a jigsaw type puzzle of the invention comprises a retainer frame having a compressible convex base for receiving said puzzle pieces on said base, a flexible transparent cover adapted to overlay said convex base, and means for securing said flexible transparent cover to said retainer frame whereby the flexible cover substantially abuts the puzzle pieces and compresses the puzzle pieces against the convex base for retaining and storing said puzzle piece. The means for securing said flexible cover to the retainer frame comprises a deep recess at one end of the retainer frame for receiving an end of the flexible cover therein and a relatively shallow recess at an opposite end of the retainer frame for receiving an opposite end of the flexible cover by depressing and sliding the opposite end of the flexible cover into the shallow recess at the said opposite end of the retainer frame. A locking device preferably is provided to prevent the flexible cover from disengaging from the retainer frame.
The convex base is comprised of a resilient material and an impermeable support surface which defines a space between the support surface and flexible cover for storing puzzle pieces when the flexible cover is secured to the retainer frame. The flexible cover preferably is transparent and is formed from plexiglass. More particularly, the puzzle storage board and container comprises a rectangular retainer frame of wood or rigid plastic having a convex base for receiving pieces of a puzzle, said retainer frame having spaced-apart upstanding side walls and spaced-apart upstanding end walls, one end wall having a deep recess formed therein and the other end wall having a relatively shallow recess formed therein, said convex base being comprised of a resilient material and a support surface, wherein the resilient material is foam material and the support surface is vinyl, and wherein the convex base has an arch in the middle of said convex base having a height of about 5/16 of an inch. A flexible transparent planar cover has an end insertable into the deep recess at one end of the retainer frame and an opposite end capable of being depressed and slid into the shallow recess at the opposite end of the retainer frame. The deep and shallow recesses are of equal height, each said recess being equivalent to the thickness of the flexible cover, plus 3/32 to 1/8 of an inch, plus the thickness of the fully depressed resilient material.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features of the invention will be more clearly understood from a consideration of the following description taken in connection with the accompanying drawings, in which:
FIG. 1 is a top perspective view of the puzzle storage board of the present invention;
FIG. 2 is a side perspective view of the said puzzle storage board preparatory to insertion of the flexible cover into a deep recess at one end of the retainer frame;
FIG. 3 is a side perspective view of the puzzle storage board illustrating the depression of the flexible cover for insertion into a shallow recess at the opposite end of the retainer frame;
FIG. 4 is a side perspective view of the puzzle storage board illustrating the flexible cover in the closed position; and
FIG. 5 is a fragmentary top plan view of the puzzle storage board illustrating an embodiment of the locking device mechanism.
DETAILED DESCRIPTION
Referring to FIGS. 1-5 of the drawings, the puzzle storage board is comprised of a rectangular retainer frame 1 and matching, transparent flexible cover 2. The retainer frame 1 is comprised of a transversely convex base 3, and shallow, upstanding side walls 4 and 5 and end walls 6 and 7. A deep recess 8 is formed in the inner side of end wall 7 and a relatively shallow recess 9 of about one-half the depth of recess 8 formed in the opposed side of end wall 6, for reasons which will become apparent as the description proceeds.
The convex base 3 should provide a semi-hard upper surface with the ability to compress or deform. Consequently, the convex base 3 is preferably comprised of an underlying compressible resilient material 12 such as foam material and a superposed resilient and smooth material 13 such as vinyl plastic disposed over a rigid underlying support surface 17.
The compressible resilient material 12 should be able to retain its ability to be deformed over repeated and lengthy periods of deformation. However, if the resilient material 12 of the convex base 3 is too soft or deep, the puzzle pieces will become displaced from each other and will be difficult to assemble. Displacement will occur when one side of a first puzzle piece is depressed in an attempt to lock a second puzzle piece in place causing the first piece to become dislodged from the rest of the assembled puzzle.
The curvature of the convex base 3 must not be too great as to require an excessive amount of force to close the flexible cover 2 nor should the curvature of the convex base 3 be too small such that the convex base 3 does not form an adequate surface for depressing puzzle pieces of different sizes. The curvature must provide an efficient combination of applied force and bed deformation. In a particular suitable embodiment, the height of the arch in the middle of the convex base 3 is approximately 5/16 of an inch for a width of 22 inches.
Generally, puzzles come in two thicknesses: a senior puzzle thickness of about 3/64 of an inch which is thinner and used in more complex puzzles and a junior puzzle of greater thickness of about 1/16 of an inch for simpler puzzles. Resilient material 12 and material 13 which have a combined deformation of approximately 3/32 to 1/8 of an inch, which is about the thickness of two senior puzzle pieces or one junior puzzle piece, is preferred.
The resilient upper material 13 of the convex base 3 should preferably be in a contrast colour to the colour of the puzzle 14 to facilitate easy assembling of the puzzle 14. Furthermore, the resilient material should be impermeable and resistant to liquids to prevent damage from the spilling of refreshments and should have a smooth texture to provide for the easy removal of debris.
Preferably, the flexible cover 2 will be transparent and formed from 3/16 inch thick plexiglass. It is preferred that either side of the flexible cover 2 be capable of being used so that the flexible cover does not become molded to the contour of the convex base 3 after lengthy storage. If the flexible cover becomes molded, it will no longer retain the puzzle pieces properly because it will not be frictionally engaged with the lips 15 and 16 of the end walls 7 and 6, respectively.
It is also preferable that the flexible cover 2 have shallow recesses (not shown) finger grips machined into each surface of the cover in proximity to each end edge of the cover to facilitate engaging and disengaging the flexible cover 2 within the retainer frame 1. The edges on the flexible cover 2 should be rounded and smooth to ensure that the edges do not damage the convex base 3, retainer frame or surface of the puzzle.
The height of each recess 8 and 9 should be identical. The height of the recesses 8 and 9 is the factor which determines the range of puzzle thicknesses which will be accommodated. Preferably, the height of each recess 8 and 9 should be equivalent to the thickness of the cover 2 plus twice the thickness of a conventional senior level piece of puzzle or one junior level piece (3/32 to 1/8 of an inch) plus the thickness of the fully depressed compressible bed material 12 and 13.
An important feature of the retainer frame 1 is to secure the flexible cover 2 in its closed position. To accomplish this, the dimensions of recesses 8 and 9 in the retainer frame 1 must be machined to within careful tolerances. These dimensions must be uniform along the entire length of each recess 8 and 9.
The retainer frame 1 and cover base 3 can be constructed of any wood or plastic material such as rigid vinyl which is suitable and cost effective for its purposes. The type of material used to fabricate the retainer frame 1 must be selected so the flexible cover 2 is frictionally engaged with lips 15 and 16 of the retainer frame 1 when the flexible cover 2 is in its closed position. However, the frictional force should not be too great as the flexible cover 2 should be capable of being removed by a child or weakened individual. Should the combination of materials for the retainer frame 1 and flexible cover 2 create too great a frictional force, the total force required to position the cover in its closed position can be adjusted by reducing the contact area between the two surfaces.
An indicator and finger access 18 preferably is formed in the bottom wall 6 of the retainer frame 1. This allows one to visually check whether or not the flexible cover 2 is in a completely closed position. In addition, the finger access 18 facilitates easy removal of the cover.
The side walls 4 and 5 of the retainer frame 1 do not require any recesses. However, the side walls 4 and 5 must be machined with an arch identical to that of the convex base 3. This eliminates any stress which might otherwise deform the contour of the convex base 3.
Referring now to FIGS. 2-4, the sequence of steps in the process for engaging the flexible cover 2 with the retainer frame 1 is illustrated. A first end 21 of the flexible cover 2 is inserted into the deep recess 8 in the inner face at wall 7 (FIG. 3). Using the lip 15 of the wall 7 for leverage, the opposite end 22 of the flexible cover 2 is depressed. Once the opposite end 22 of the flexible cover 2 is below the height of the lip 16 of the bottom wall 6, the said end 22 of the flexible cover can be slid into recess 9 of wall 6 (FIG. 4). The flexible cover 2 is then held in place by frictional engagement with lips 15 and 16 and locking device 10.
The locking device 10, as illustrated more clearly in FIGS. 1, 4 and 5, is a cam rotationally mounted in wall 7 by pin 11 and juxtaposed with the flexible cover 2 by rotating the cam 10 about pin 11. The locking device 10 prevents the flexible cover 2 from disengaging from the retainer frame 1 by sliding past lip 16 of the wall 7.
The flexible cover 2 thus is locked in place and effectively sandwiches the puzzle 14 between the flexible cover 2 and the convex base 3.
It will be understood, of course, that modifications can be made in the embodiment of the invention illustrated and described herein without departing from the scope and purview of the invention as defined by the appended claims.
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A portable puzzle storage board provides an assembly surface for jigsaw type puzzles and a simple mechanism for securing the puzzle pieces in place. The pieces are secured with a flexible cover which may be easily engaged and disengaged with the retainer frame of the puzzle storage board to provide a simple and quick way of storing a completed puzzle or partially assembled puzzle. The puzzle storage board is comprised of a flexible cover, a retainer frame having a convex base for receiving the puzzle pieces, and a recess for securing the flexible cover to the retainer frame for retaining the puzzle pieces.
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FIELD
[0001] The present document relates to a filtration and recovery system for a solvent-based liquid.
SUMMARY
[0002] In an embodiment, a filtration and recovery system may comprise a filtration tank, the filtration tank defining a filter chamber in fluid flow communication with a first opening for the ingress of a solvent-based liquid and the egress of a by-product, a second opening for initial draining of the solvent-based liquid, and a third opening for the egress of the solvent-based liquid, the filtration tank having a plurality of filters for filtering the solvent-based liquid in a filtration procedure, the plurality of filters being adapted to accumulate the by-product during the filtration procedure, and a recovery tank in fluid flow communication with the filtration tank through a main drain in communication with the first opening and an auxiliary drain in communication with the second opening, the recovery tank including a front portion and a back portion defining a slanted surface, the slanted surface in communication with a filter portion having a secondary filter for filtering the by-product, wherein the filtration tank and the recovery tank establish a non-pressurized system for the movement of the by-product.
[0003] Additional features will be set forth in the description which follows or will become apparent to those skilled in the art upon examination of the drawings and detailed description which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 is a simplified block diagram showing a filtration and recovery system;
[0005] FIG. 2 is a perspective view of the filtration and recovery system;
[0006] FIG. 3 is another perspective view of the filtration and recovery system;
[0007] FIG. 4 is a simplified partial cross-sectional side view of the filtration and recovery system;
[0008] FIG. 5 is a side view of a recovery tank of the filtration and recovery system;
[0009] FIG. 6 is a front view of the recovery tank;
[0010] FIG. 7 is a top view of the recovery tank;
[0011] FIG. 8 is a perspective view of the recovery tank shown in partial phantom lines;
[0012] FIG. 9 is a cross-sectional view of the recovery tank taken along line 9 - 9 of FIG. 7 illustrating the direction of flow into a secondary filter disposed inside the recovery tank; and
[0013] FIG. 10 is flow chart illustrating the operation of the filtration and recovery system.
[0014] Corresponding reference characters indicate corresponding elements among the view of the drawings.
DETAILED DESCRIPTION
[0015] Referring to the drawings, an embodiment of filtration and recovery system is illustrated and generally indicated as 10 in FIG. 1 . The filtration and recovery system 10 may include a filtration tank 12 for conducting a filtration procedure that filters a solvent-based liquid (not shown) used in a dry cleaning process 16 . In one embodiment, the dry cleaning process 16 may utilize a single dry cleaning machine (not shown) with the filtration and recovery system 10 , although in other embodiments the dry cleaning process 16 may include a plurality of dry cleaning machines. In another embodiment, the filtration and recovery system 10 may filter any type of solvent-based liquid used for other types of processes other than the dry cleaning process 16 .
[0016] The filtration tank 12 may be in fluid flow communication with a recovery tank 14 for recovering solvent-based liquid contained in a by-product that is produced in the filtration tank 12 during the filtration procedure as shall be discussed in greater detail below. In addition, the filtration tank 12 and recovery tank 14 are in fluid flow communication with a reservoir 18 that stores solvent-based liquid filtered during the filtration procedure or recovered from the by-product inside the recovery tank 14 during a recovery procedure as shall also be discussed in greater detail below.
[0017] As shown, the filtration and recovery system 10 may include a microprocessor 20 for controlling the filtration and recovery procedures. The microprocessor 20 may be operatively associated with a multi valve arrangement having a first valve 50 , second valve 52 and third valve 54 for controlling the flow of the solvent-based liquid as well as the flow of by-product during operation of the filtration and recovery system 10 . In one embodiment, first, second and third valves 50 , 52 and 54 may be hydraulic or air pressure valves for permitting or preventing fluid flow communication.
[0018] Referring to FIGS. 2-7 , filtration tank 12 may define a filter chamber 30 in communication with a first opening 42 adapted for the ingress of the solvent-based liquid into the filter chamber 30 during the filtration procedure as well as egress of by-product from the filter chamber 30 during the recovery procedure. The filter chamber 30 also communicates with a second opening 43 for allowing the solvent-based liquid to be initially drained during the recovery procedure. As shown, first opening 42 communicates with a conduit 88 that is engaged to a coupling 86 , such as a conventional Tee, that permits either the entry of solvent-based liquid used during the filtration procedure or the removal of by-product from the filter chamber 30 during the recovery procedure. The first valve 50 may communicate with the coupling 86 which is operable between an open position, wherein solvent-based liquid used during the dry cleaning process 16 is allowed to enter the filtration tank 12 and a closed position, wherein solvent-based liquid is prevented from entering the filtration tank 12 .
[0019] The coupling 86 may also communicate with a main drain 22 through second valve 52 that allows by-product to be removed from the filtration chamber 30 during the recovery procedure. Second valve 52 may be operable between an open position, wherein by-product may enter the main drain 22 for entry into the recovery tank 14 during the recovery procedure and a closed position, wherein the solvent-based liquid is prevented from entering the main drain 22 during the filtration procedure.
[0020] As shown, second opening 43 is in selective fluid flow communication with an auxiliary drain 24 through the third valve 54 . Third valve 54 is operable between an open position, wherein solvent-based liquid inside the filter chamber 30 can be initially drained during the first phase of the recovery procedure to a level where the second opening 43 communicates with the filter chamber 30 .
[0021] As further shown, a plurality of spin filters 26 are operatively disposed inside the filter chamber 30 for filtering the solvent-based liquid of by-product, such as dirt, grease, particulates, fibers and other materials that may become entrained in the solvent-based liquid during the dry cleaning process 16 . The plurality of spin filters 26 may be mounted on a hollow tubular member 38 which extends along the axis of the filtration tank 12 and defines a conduit 78 in communication with a third opening 45 for permitting solvent-based liquid to exit the filtration tank 12 after filtration and return to the reservoir 18 . In one embodiment, the hollow tubular member 38 defines a plurality of openings 76 in communication with a respective spin filter 26 mounted by a collar (not shown) such that solvent-based liquid that has been filtered by each spin filter 26 enters the conduit 78 of the tubular member 38 and exits third opening 45 for storage in the reservoir 18 .
[0022] As a result of this filtration procedure, by-product can accumulate on the spin filters 26 over time. The filtration tank 12 may include a motor 34 in operative engagement with one end of the tubular member 38 through a gear assembly 46 that rotates the mounted spin filters 26 in a spinning motion when directed by microprocessor 20 . This spinning motion dislodges and removes the by-product that has accumulated on the spin filters 26 due to the centrifugal force generated by the spinning motion of the spin filters 26 . The by-product then falls by force of gravity after removal from the spin filters 26 to the bottom portion of the filter chamber 30 . When first valve 50 is in the closed position and second valve 52 is in the open position during the recovery procedure, the by-product can be channeled through first opening 42 and into main drain 22 such that the by-product can enter the recovery tank 14 for the recovery of solvent-based liquid contained in the by-product.
[0023] Referring to FIG. 4 , recovery tank 14 may define a recovery chamber 32 that includes an inlet 44 in communication with main drain 22 for the entry of by-product removed from the filtration tank 12 during the recovery procedure. In addition, the recovery tank 14 may define a back portion 66 and a front portion 68 in communication with an upper portion 60 and a lower portion 62 . The lower portion 62 may define a slanted surface 72 that slants downwardly from the back portion 66 to the front portion 68 such that the slanted surface 72 terminates at a filter portion 64 located below the front portion 68 .
[0024] In one embodiment, the slanted surface 72 may have a vertical drop of 6 inches from the front portion 68 to the back portion 66 , however it is contemplated that the slanted portion 72 may be set at any angle sufficient to permit by-product that enters inlet 44 to flow downwardly along slanted surface 72 by the force of gravity alone in a non-pressurized system during the recovery procedure.
[0025] As further shown, the upper portion 60 may define an overflow opening 56 in communication with a tubular member 94 adapted to permit the overflow of by-product inside the recovery chamber 32 to drain from the recovery tank 14 and into the reservoir 18 . In addition, the upper portion 60 may define a wash down opening 58 adapted to permit entry of a hose for washing down the recovery chamber 32 of residual by-product.
[0026] Referring to FIG. 2 , the inlet 44 may communicate with the front portion 68 such that any by-product that enters inlet 44 from the main drain 22 is channeled downwardly by the force of gravity along the slanted portion 72 such that the by-product enters the filter portion 64 . The filter portion 62 may include a detachable secondary filter 28 adapted to filter the by-product such that solvent-based liquid contained in the by-product may be recovered and stored in reservoir 18 . In addition, a vent tube 90 may be provided that has an upper end 96 in communication with front portion 68 and a lower end 98 in communication with the filter portion 64 . The vent tube 90 is adapted to permit equalization of pressure between the front portion 68 and the filter portion 64 of the recovery chamber 32 during the recovery procedure.
[0027] In one embodiment, the detachable secondary filter 28 may be a filter basket made from a material adapted to permit solvent-based liquid to filter through while retaining residual by-product within the filter basket which may then be later removed from the filter portion 64 in order to dispose of the residual by-product. Referring to FIG. 7 , the upper portion 60 of the recovery tank 14 may include a door 70 that permits access to the recovery chamber 32 so that the detachable secondary filter 28 may be removed as noted above.
[0028] The filtration tank 12 and recovery tank 14 may be engaged to a support 36 in order to provide a structural base for the filtration and recovery system 10 . As shown, the support 36 may have a pair of front legs 80 and a pair of back legs 82 for supporting the recovery tank 14 . The support 36 may further include a pair of upper legs 84 engaged to the recovery tank 14 which, in combination with the back legs 82 , support the filtration tank 12 such that the tank 12 is angled downwardly towards the rear legs 84 as illustrated in FIG. 4 . This downward orientation of the filtration tank 12 permits the by-product to be evacuated by force of gravity alone from the bottom portion of the filter chamber 30 and into the recovery tank 14 through the main drain 22 .
[0029] Referring to FIGS. 4 , 8 - 10 , the method of operation for the filtration and recovery system 10 will be discussed in greater detail. As shown in FIG. 10 , at step 100 the filtration procedure is initiated such that the microprocessor 20 places first valve 50 in an open position in order to permit solvent-based liquid used in the dry cleaning process 16 to enter the filtration tank 12 through first opening 42 , while second valve 52 and third valve 54 are placed in the closed position in order to prevent solvent-based liquid from entering the recovery tank 14 . During the filtration procedure solvent-based liquid from the dry cleaning process 16 flows into the filtration tank 12 through first opening 42 , as illustrated by flow A, and fills the filter chamber 30 such that solvent-based liquid enters and is filtered by the spin filters 26 and exits third opening 45 , as illustrated by flow B, such that filtered solvent-based liquid enters reservoir 18 .
[0030] After a predetermined period of time has expired, the filtration procedure is temporarily terminated by the microprocessor 20 and the recovery procedure may then be initiated by turning off the pump (not shown) that drives the solvent-based liquid from the dry cleaning machine(s) during the dry cleaning process 16 at step 102 . The microprocessor 20 at step 104 then places first valve 50 in the closed position in order to prevent any further solvent-based liquid from entering the filtration tank 12 as well as placing third valve 54 in the open position in order to allow the solvent-based liquid inside filter chamber 30 to be initially drained from the filtration tank 12 .
[0031] At step 106 , the solvent-based liquid is allowed to drain through the auxiliary drain 24 as illustrated by flow C and into the recovery tank 14 until the solvent-based liquid reaches the level of the second opening 43 inside the filter chamber 30 . Once the filtration tank 12 is sufficiently drained, the microprocessor 20 at step 108 engages the motor 34 with the gear assembly 46 such that the tubular member 38 is rotated in one direction in a centrifugal operation that removes by-product from the plurality of spin filters 26 for a predetermined amount of time. In one embodiment, the centrifugal operation is conducted for 15 seconds and then terminated for 15 seconds over a period of 3 minutes; however, other predetermined periods of time for cycling the centrifugal operation are contemplated.
[0032] This centrifugal operation agitates the spin filters 26 such that by-product is removed and allowed to accumulate at the bottom of the filter chamber 30 . In one embodiment, the centrifugal operation may rotate in one direction during one cycle and then rotate in the opposite direction in the next cycle in order to remove by-product from the spin filters 26 .
[0033] After the centrifugal operation is completed, at step 110 a rest period, for example 10-15 seconds, is conducted. At step 112 , the microprocessor 20 may then place second valve 52 in the open position, while first valve 50 remains in the closed position and third valve 54 remains in the open position. This valve arrangement permits the by-product accumulated along the bottom portion of the filter chamber 30 to be evacuated through the main drain 24 and into the recovery tank by force of gravity as illustrated by flow D.
[0034] At step 114 , the recovery procedure is initiated for recovery of solvent-based liquid from the by-product. During the recovery procedure, the by-product contacts the slanted portion 72 upon entering the recovery chamber 32 of the recovery tank 14 through the inlet 44 and is channeled toward the filter portion 64 in a gravity feed movement. As by-product is channeled towards the filter portion 64 the by-product enters the secondary filter 28 for filtration. During the recovery procedure, by-product accumulates in the secondary filter 28 inside the filter portion 64 so that any solvent-based liquid contained in the by-product is filtered through the secondary filter 28 and may exit through a filter outlet 92 located at the bottom of the filter portion 64 as illustrated by flow E. After exiting the filter outlet 92 , the solvent-based liquid is transported to the reservoir 18 for use in the dry cleaning process 16 . In one embodiment, by-product may be allowed to exit the filtration tank 12 and enter the recovery tank 14 for 30 seconds, although other times are contemplated. After the recovery procedure is completed, at step 116 , the microprocessor 20 places the second valve 52 and the third valve 54 in the closed position, while placing the first valve 50 in the open position in order to once again initiate the filtration procedure as noted above.
[0035] Once a sufficient amount of by-product has accumulated in the secondary filter 28 , secondary filter 28 with the accumulated by-product therein may be removed through the door 70 of the recovery tank 14 . The secondary filter 28 may then be inserted back into the filter portion 64 for further filtering of by-product from the filtration tank 12 .
[0036] It should be understood from the foregoing that, while particular embodiments have been illustrated and described, various modifications can be made thereto without departing from the spirit and scope of the invention as will be apparent to those skilled in the art. Such changes and modifications are within the scope and teaching of this invention as defined in the claims appended hereto.
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A solvent filtration and recovery system for filtration and recovery of a solvent-based liquid used in dry cleaning includes filtration tank having filter chamber with motor-driven spin filters which are selectively operated. A valve and conduit arrangement allows the liquid from dry cleaning to enter the filter chamber for filtering and flows out as filtered liquid while the spin filters are not rotating. The arrangement allows initial at least partial draining of the solvent-based liquid in the filter chamber after such filtration procedure. A recovery tank is in communication with the filtration tank through a main drain. A motor drives the spin filters during a recovery procedure, in which centrifugal force caused by the rotating spin filters for a predetermined amount of time removes by-product from the spin filters, which is drained off from the filtration tank. A reservoir stores the solvent-based liquid and receives the liquid from both the recovery tank and the filtration tank. Operation is microprocessor implemented and controlled.
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FIELD OF THE INVENTION
The invention relates to an optical apparatus, especially a scanning microscope, wherein an expanded laser beam is divided into several partial beams by micro lenses arranged next to one another, wherein each partial beam is focused onto a focal point by a common objective lens to optically excite a sample, and wherein fluorescent light emanating from the individual focal points of the sample is registered by a photo sensor arranged behind the lens as seen from the sample.
BACKGROUND OF THE INVENTION
Typically, such an optical apparatus includes a junction device for the beam path, for example a beam splitter. The junction device is located between the light source of the laser beam and the sample. Consequently, the fluorescence light emanating from the sample is deflected laterally away from the direction of the excited laser beam and towards the photo sensor.
A scanning microscope is known from Nature, Vol. 183, page 760. Several partial beams are formed from an expanded laser beam. The partial beams are focused by a common objective lens to optically excite a sample. A photo sensor arranged behind the objective lens, as seen from the sample, registers fluorescence light of the focal points which emanates from the sample. Several partial beams are formed from the laser beam by a screen or an aperture arrangement having several holes. The screen or aperture arrangement is arranged in the optical path of the apparatus, so that the fluorescence light coming from the sample has to pass through the screen when it is to contact the photo sensor. Consequently, the apparatus is a confocal scanning microscope in which only fluorescence light coming from one plane of the sample contacts the photo sensor. Thus, a three-dimensional resolution of the sample with respect to the attained fluorescence light intensities is possible. The screen or aperture arrangement of the scanning microscope is a so-called “Nipkow disc” having holes arranged therein to scan the sample uniformly by rotating the “Nipkow disk” about its center. The “Nipkow disk” was originally designed to scan pictures to attain a signal to be send by telegraph.
A problem of the known scanning microscope is that the holes of the blind must have a certain minimum lateral distance between one another to prevent fluorescence light emanating from a plane of the sample other than the plane to be observed and not being focused back to the origin hole of the exciting radiation from passing through holes adjacent to the origin hole and onto the photo sensor. A great distance between the holes within the blind results in the luminous power of the laser beam substantially fading out due to the aperture arrangement and consequently not being used. Additionally, the laser light faded out by the aperture arrangement is reflected onto the photo sensor from the rear side of the aperture arrangement and causes great background.
To solve this problem, it is suggested in Nature, Vol. 338, pages 804 through 806, to arrange the holes of the aperture arrangement especially close to one another, knowing that light unfocused with respect to the origin hole passes through adjacent holes of the aperture arrangement and onto the photo sensor. The light resulting from the background is to be compensated by considering a light intensity distribution recorded by a photo sensor prior to the compensation and without making use of the aperture arrangement. After that, the light intensity distribution recorded without the aperture arrangement is subtracted from light intensity distribution recorded using the aperture arrangement. This procedure may cause difficulty since the background to be subtracted may have a greater dimension than the signal to be observed. Consequently, extreme defects may occur in the revised signal.
A scanning microscope is known from U.S. Pat. No. 5,034,613. Fluorescence light of the sample is registered by the photo sensor. The fluorescence light has a wavelength which is half as long as the wavelength of the laser beam. The fluorescence of the sample is based on a two photons excitation. The probability of such a two photons excitation differs substantially from zero exclusively in the core region of each focal point in which the laser beam is focused for optical excitation of the sample. Thus, the scanning microscope has a substantially improved axial resolution compared to confocal scanning microscopes. Nevertheless, the yields of fluorescence light of the sample are relatively smaller compared to a confocal scanning microscope. Thus, measuring times necessary for each sample to attain meaningful fluorescence light intensities are increased. The scanning of a sample in all three dimensions takes a much longer period of time compared to a confocal scanning microscope. Furthermore, the laser beam of the known scanning microscope making use of the two photons excitation is only focused in one focal point to excite the sample. The yield of fluorescence light of this focal point can be increased by increasing the luminous power of the laser beam. However, the possibility of increasing the luminous power of the laser beam is strictly limited since otherwise a local change of the sample occurs due to overheating.
From the German Patent Application 40 40 441 another scanning microscope is known. A laser beam is divided into two portions, and the two portions coming from opposite directions are brought to interference in a common focal point to excite a sample. With the interference, a main maximum and two secondary maxima of the light intensity occur in the region of the common focal point of the two partial beams. The main maximum has a smaller axial extension and is easily separable from the secondary maxima by a confocal arrangement. The small axial extension of the main maximum implies a very good axial resolution of this known scanning microscope.
A scanning microscope of the type mentioned at the beginning is known from Bioimages 4 (2): 57-62, June 1996. The micro lenses are arranged to form a micro lens wheel. The laser beam is divided into partial beams, and the sample is scanned in two dimension by rotating the micro lens wheel about its axis extending in parallel to the laser beam. A aperture wheel including one aperture opening for each micro lens is arranged behind the micro lens wheel. The partial beam directed onto the sample, as well as the fluorescence light excited by this partial beam and coming from the direction of the sample, enter through the aperture openings to attain a sufficient resolution in depth for this known scanning microscope using one photon excitation. The arrangement and the support of the micro lens wheel and of the aperture wheel have to be executed extremely accurate to assure a perfect function of the known scanning microscope. Since the micro lenses in the known micro lens wheel are not arranged side by side in two dimension, but in bent rows instead, as it is realized in a usual “Nipkow disk”, not the entire light intensity of the expanded laser beam is used.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an optical apparatus, i.e. especially a scanning microscope, of the type mentioned at the beginning that makes it possible to use most of the luminous power of an expanded laser beam without the requirement of adjusting being great.
According to the present invention, this object is achieved by an optical apparatus, i.e. especially a scanning microscope, of the type mentioned at the beginning, in which each photon of the fluorescent light coming from the sample and being registered by the photo sensor is excited by at least two photons of the laser beam in the sense of a two-photons-process. This means that the novel apparatus makes use of a several photons excitation. Due to the excitation by several photons, a sufficient resolution with respect to depth is attained without having to use screens or apertures arranged behind the micro lenses and in front of the photo sensor.
The invention is applicable to all scanning microscopes using a several photon excitation to increase the axial resolution. That implies that the laser beam may also include laser radiation of various wavelengths. In this case, the wavelengths are differently related to the wavelength of the fluorescence light coming from the sample than it is described above. Usually, the wavelength of the fluorescence light is shorter than the shortest wavelength of the laser beam used for excitation.
For example, a scanning microscope according to the present invention may be characterized by the fact that the wavelength of the laser beam is approximately twice as long as the wavelength of the fluorescent light coming from the sample and being registered by the photo sensor. This fact corresponds to a two photons excitation of the fluorescence light or a two-photons-process. A variety of filters may be used to completely separate the fluorescence light from the laser radiation since the fluorescence light and the laser radiation have different wavelengths.
The micro lenses may be arranged directly adjacent to one another, so that the laser beam is used along its entire width. At the same time, no laser light is reflected by the micro lenses. The beam paths of the partial beams are easily separable after the micro lenses. The partial beams are focused in the focal points of the micro lenses. In this way, punctual light sources are realized in the focal points. By the objective lens, these punctual light sources are imaged into the plane of the sample to be observed. The punctual light sources have a lateral distance between one another corresponding to the diameter of the utilized micro lenses.
The micro lenses may have a common focal length and may be arranged in a plane oriented perpendicularly to the laser beam. Thus, the focal points of the micro lenses are also located in a common plane, and they are imaged into one plane of the sample. Due to the separation of the laser beam into several partial beams by the micro lenses, the scanning process of the sample is accelerated in this plane compared to the use of only one focal point in which the sample is excited.
The micro lenses may have different focal lengths and/or may be arranged in parallel planes oriented perpendicularly to the laser beam. Consequently, the focal points of the micro lenses have different axial position, and they are imaged into different planes of the samples. By scanning the sample, several planes of the sample are scanned at the same time.
The several micro lenses used in the novel apparatus are herein designated as a micro lens array. Such a micro lens array may be made of one piece by blank pressing. Typically, the micro lens array has an extend of several millimeters, for example 5 mm, in a perpendicular direction to the laser beam.
The micro lenses may be arranged side by side in one direction. This arrangement is advantageous when the laser beam has been expanded in only one direction by use of two bar-shaped lenses. In case of an arrangement of the micro lenses side by side in only one direction, the focal points are also provided to excite the sample in this arrangement.
To excite the sample simultaneously in a greater number of focal points, the micro lenses within the micro lens array may be arranged side by side in two directions. Such a two-dimensional micro lens array typically includes approximately 100 single micro lenses.
The micro lenses may be arranged to form a micro lens wheel, wherein the expanded laser beam is divided into the partial beams by some of the micro lenses, and wherein the sample is scanned in two or three dimensions by rotating the micro lens wheel about its axis extending in parallel to the laser beam. To scan the sample in three dimensions, the micro lenses of the micro lens wheel have to have different focal lengths, or have to be arranged in different distances to the sample.
It is not advantageous to also lead the fluorescence light coming from the sample back through the micro lens array to attain a strict confocal arrangement.
Other objects, features and advantageous of the present invention will come apparent to those skilled in the art upon review of the following specification, when taken in conjunction with the accompanying drawing. The fluorescence light should be deflected laterally outside the optical path and imaged onto a photo sensor. In case of the photo sensor being a CCD-array, an aperture arrangement or a screen can be simulated in front of the photo sensor by controlling the CCD-array, so that a confocal arrangement of the scanning microscope is achieved effectively, without the requirement of adjustment being as great as it is using a physical aperture arrangement.
The novel micro lens array may also be used with a scanning microscope in which the axial resolution is increased by interference of laser radiation coming from two directions. In this case, the laser beam divided into the partial beams by the micro lenses is divided by a beam dividing device, and the partial beams are brought to interference in the region of the sample from opposite directions. In each of the focal points into which a focal point of a micro lens is imaged, an interference maximum occurs in which the optical excitation is achieved.
The novel optical apparatus is not only advantageous in case of being used as a scanning microscope. Also, it can be used as a testing apparatus to test lenses and combinations of lenses. For the testing, the lenses are inserted into the apparatus as objective lenses. For example, the sample may consist of a fluid including a fluorescent material having a defined, homogeneous concentration. Thus, in case of a relative motion of the objective lens with respect to the micro lens array, a change of the fluorescence light intensities registered by the photo sensor must not occur, when the lens or the lens combination, respectively, does not have any defects.
The invention is explained and described in greater detail with respect to embodiments. In the following, it is always referenced to a scanning microscope, although the above described testing apparatus for lenses or lens combinations would have the identical arrangement.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the arrangement of a first embodiment of a scanning microscope according to the present invention.
FIG. 2 illustrates a detail of a second embodiment of the scanning microscope according to the present invention.
FIGS. 3-8 each are illustrations of embodiments of micro lens arrays used in combination with the scanning microscope according to the present invention.
FIG. 9 illustrates a third embodiment of the scanning microscope according to the present invention.
FIG. 10 illustrates an enlarged detail of the scanning microscope according FIG. 9 .
FIG. 11 is an illustration of another embodiment of a micro lens array used in combination with the scanning microscope according to the present invention.
DETAILED DESCRIPTION
FIG. 1 illustrates a scanning microscope 1 . An expanded laser beam 2 coming from a laser and an expanding optical device (both not shown) is divided into several partial beams 4 by a micro lens array 3 . The micro lens array 3 includes a multiplicity of micro lenses 5 arranged side by side. Each micro lens 5 focuses one partial beam 4 in its focal point 6 . Each focal point 6 forms a punctual source of light which is imaged into a sample 8 by an objective lens 7 . The image is illustrated by the beam paths 9 and 10 of the two outer partial beams 4 . Each partial beam 4 is focused in a focal point 11 , and in each focal point 11 the material of the sample 8 is optically excited to fluorescence. The fluorescence light passes through the objective lens 7 , and by a tilted mirror 12 onto a photo sensor 13 . To clearly illustrate the focal points 11 on the photo sensor 13 , the beams paths of the two outer focal points 11 are shown and are designated with 9 ′ and 10 ′. The images 14 of the focal points 11 on the photo sensor 13 have the same lateral distance between one another as the focal points 6 of the micro lenses 5 . The entire laser beam 2 is used for the partial beams 4 with the micro lenses 5 , so that at a given luminous power of the laser 2 , the maximum optical excitation of the sample 8 occurs in the focal points 11 . This is advantageous since a several photons excitation is observed to increase the axial resolution of the scanning microscope 1 in the direction of the optical axis 15 of the objective lens 7 . The concentration of the fluorescence radiation onto the region around the geometric focal points 11 is great enough not to use a screen or an arrangement of apertures in front of the photo sensor 13 , as it is necessary to confocal scanning microscopes to increase the axial resolution. Nevertheless, when an aperture arrangement is simulated by a software, by controlling the photo sensor 13 preferably being a CCD-array, the scanning microscope 1 according to FIG. 1 may also be used to observe a one photon excitation of the sample in the focal points 11 .
FIG. 2 illustrates the arrangement of a blind 16 in front of the photo sensor 13 in another embodiment of the scanning microscope 1 according to FIG. 1 .
The micro lenses 5 of the micro lens array 3 of the embodiment of the scanning microscope 1 illustrated in FIG. 1 are arranged in one common plane, and the micro lenses 5 all have the same focal length, so that the focal points 6 are located in one common plane 17 . This is not true for the embodiments illustrated in FIGS. 3 and 4. According to FIG. 3, the micro lenses 5 of the micro lens array 3 are displaced axially with respect to one another. Since the micro lenses 5 have the same focal length, the focal points 6 are axially displaced with respect to one another by the same way as the micro lenses 5 . Correspondingly, the focal points 6 are displayed in different planes of the sample 8 . Thus, the sample 8 is excited in several adjacent planes when the micro lens array 3 according to FIG. 3 is used.
Such an excitation in several planes is also attainable by different focal lengths of the micro lenses 5 of the micro lens array 3 , as this is illustrated in FIG. 4 . One half of the micro lenses 5 has a shorter focal length than the other half of the micro lenses 5 . The focal points 6 ′ of the one half of the micro lenses 5 are located in a different plane than the focal points 6 ″ of the other half of the micro lenses 5 . Thus, the sample 8 is optically excited in two parallel planes.
While preferred embodiments of the invention have been disclosed in the foregoing specification, it is understood by those skilled in the art that variations and modifications thereof can be made without departing from the spirit and scope of the invention, as set forth in the following claims. Moreover, the corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims are intended to include any structure, material, or acts for performing the functions in combination with other claimed elements, as specifically claimed herein.
FIG. 5 shows a top view of a micro lens array 3 in which the micro lenses 5 are arranged side by side in only one direction and perpendicularly to the laser beam shining in from the direction of view. As illustrated in FIG. 6, such a micro lens array 3 is designed to expand a laser beam 2 in only one direction by means of bar-shaped lenses 18 .
FIGS. 7 and 8 illustrate two embodiments of the micro lens array 3 in which the micro lenses 5 are arranged side by side in two directions. These micro lens arrays 3 are designed to accomplish a two-dimensional expansion of the laser beam 2 . The shape of the micro lens array 3 according to FIG. 8 corresponds better to the cross section of a laser beam being usually circular than the rectangular shape of the micro lens array 3 of FIG. 7 .
FIG. 9 illustrates a scanning microscope 1 . The expanded laser beam 2 is divided into several partial beams. These partial beams are not shown in detail. Only one beam path 19 is illustrated. After passing a beam separator 20 , the beam path 19 is divided into two paths 21 and 22 . The separated partial beams are lead in opposite directions to two objective lenses 7 via the two paths 21 and 22 . The objective lenses superimpose the separated partial beams in the region of the sample 8 . In case of the partial beams consisting of monochromatic, coherent light, an interference pattern including one main maximum and two secondary maxima in the region of the focal point 11 occurs for two partial beams 4 , as it is illustrated in FIG. 10 . The main maximum 24 and the secondary maxima 25 are spaced apart from each other in the direction of the optical axis 15 of the objective lenses 7 , so that the fluorescence light can be discriminated by a confocal arrangement of a photo sensor, so that exclusively fluorescence light from the region of the main maximum is registered. When a several photons excitation is observed, this discrimination occurs automatically due to the different probabilities of excitation in the main maximum 24 and in the secondary maxima 25 .
The invention to divide the laser beam 2 by a micro lens array 3 including a multiplicity of single micro lenses 5 is applicable to many different types of scanning microscopes. The entire light intensity of the laser beam 2 is always used. This is advantageous, when a several photons excitation is observed, since the likelihood of this excitation is much less than the likelihood of a single photon excitation.
The embodiment of the micro lens array shown in FIG. 11 suits to scan a sample with the focal points of the partial beams of the laser beam 2 in two dimensions or in three dimensions. The micro lenses 5 are arranged to form a micro lens wheel 26 . Substantially, the entire expanded laser beam 2 is divided into partial beams by some of the micro lenses 5 arranged side by side in two dimensions, since only these micro lenses 5 are illuminated. By turning the micro lens wheel 26 about its axis 27 extending in parallel to the laser beam, the micro lenses 5 are moved with respect to the sample, and different lenses are used to divide the laser beam 2 . As a result, the sample is scanned in two or three dimensions depending on whether the micro lenses 5 have one focal length and their focal points 6 are located in one plane as shown in FIG. 6, or whether they are displaced with respect to one another as illustrated in FIGS. 3 and 4. When the frequency of scanning the sample by the micro lens wheel 26 is high enough, the fluorescence light coming from the sample can be observed in the region of the photo sensor or via an additional eyeglass directly with the eye or as a picture. It is advantageous to use an IR-filter to exclude scattered excitation light. A frequency sufficient to directly observe the image with the eye is, for example, attained when the micro lenses 5 forming the micro lens wheel 26 cover the entire sample five times with each rotation of the micro lens wheel 26 , and when the micro lens wheel 26 is rotated about its axis 27 with a frequency of 75 Hz. The direct observation of a sample during its several photons excitation was not possible prior to the invention due to the low fluorescence yield per time unit in the prior art.
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An optical apparatus, especially a scanning microscope ( 1 ), wherein an expanded laser beam ( 2 ) is divided into several partial beams ( 4 ) by micro lenses ( 5 ) arranged next to one another. Each partial beam ( 4 ) is focused onto a focal point ( 11 ) by a common objective lens ( 7 ) to optically excite a sample ( 8 ). Fluorescent light emanating from the individual focal points ( 11 ) of the sample ( 8 ) is registered by a photo sensor ( 13 ) arranged behind the objective lens ( 7 ) as seen from the sample ( 8 ). Each photon of the fluorescent light coming from the sample ( 8 ) and being registered by the photo sensor ( 13 ) is excited by at least two photons of the laser beam ( 2 ).
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FIELD
The present invention relates to high-efficiency, low complexity, chemical, liquid-fueled rocket propulsion systems.
BACKGROUND
One characterization of the efficiency of a rocket propelled vehicle, particularly one having a chemical propulsion system, is the mass ratio MR of the vehicle defined as the final mass of the vehicle (after propellants are consumed) over the initial mass of the vehicle (before propellants are consumed). The higher the MR, the more total vehicle and payload mass are carried by a unit of propellant, and the less propellant is used merely to carry later-consumed propellant. For a given MR, the proportion of the final vehicle mass available for payload may be increased by weight reduction techniques in the non-payload components, such as use of composite materials and the like.
MR itself can be improved by staging, which allows portions of the system no longer useful to be discarded so that later stages accelerate a smaller total mass. Staging adds significantly to the complexity of a propulsion system, however.
MR may also be improved by increasing the specific impulse (I SP ) of a propulsion system, with I SP defined as the pounds of thrust divided by the mass flow rate in pounds per second of propellant exhaust flowing from the engine of the system, or as the seconds of pounds of thrust per pound of propellant materials. MR increases exponentially as a function of I SP . Simply put, the longer and larger the thrust provided from a given weight of propellant, the more propellant energy is available to accelerate the payload and other system components. The lsp of a system can be improved in various ways, including increasing the exhaust velocity of the system such as by increasing the reaction temperature and/or pressure, and increasing the completeness of the reaction of the propellant substance(s). All such improvements should be achieved with minimum added weight, however, or even with weight reduction, if possible.
Liquid fueled rocket propulsion systems generally require some means of delivering propellant to a thrust chamber under pressure. Stored pressurized gas may be used to drive propellant to the thrust chamber (known as a “blowdown system”), but the storage and handling systems for the gas take up valuable space and weight allotments. The required mass of the propellant tankage is proportional to the pressure applied to the propellant, which must exceed the chamber pressure of the engine. Since high chamber pressures are required for maximum I SP , such systems are penalized by the increased tankage mass. One or more pumps may be used to pressurize the propellant, but weight must be minimized and efficiency maximized. Such pumps require energy, in most advanced engines this is provided by turbines powered by the fuel and oxidizer, through combustion or as a byproduct of heating through regenerative cooling.
Rocket propulsion systems that are intended to operate continuously for significant lengths of time further require cooling of the combustion chamber and thrust nozzle. Such cooling should be performed as efficiently as possible with a minimum consumption of energy and/or propellant.
SUMMARY
The present invention provides a greatly simplified, efficient liquid-fueled rocket propulsion system. The system includes a rocket engine having a rotor assembly with an ultracentrifugal (over 200 meters/second tangential velocity) liquid pump arranged around a combustion chamber so as to provide both forced convective and Coriolis-effect and centripetal-acceleration enhanced free convective regenerative cooling to the combustion chamber while pressurizing the liquid propellant. Both fuel and oxidizer may be stored at cryogenic temperatures and pumped around the combustion chamber for regenerative cooling. The combustion chamber may be structured to rotate together with the pump to provide Coriolis-effect and centripetal-acceleration enhanced combustion. The rotor assembly is driven directly by a tangential component of the primary thrust vector by means of tilted nozzles or by vanes, flutes or other reaction surfaces. Liquid oxygen and liquid propane, liquid methane or another thermally compatible fuel, maintained at about the same temperature and pressure, may be used as both propellant and coolant, and may be stored in polyethylene terephthalate (PET) or other polymer tankage. The rotor assembly may be the only moving part of the engine, and may comprise the combined functionality of combustion chamber, turbine, pump, and cooling channels, and may desirably be rotated at the highest possible speed to obtain the highest feasible pressures.
This engine is desirably of the plug or aerospike variety, and can be combined with a conventional bell nozzle of various geometries to give proper expansion ratios for the exhaust gasses.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic cross section of an embodiment of a rocket engine according to one embodiment of the present invention.
FIG. 2 is a cross-sectional view of the spindle 12 of the engine of FIG. 1 .
FIG. 3 is an axial plan view of the rotor 10 of the engine of FIG. 1 .
FIG. 4 is a cross-sectional view of the rotor 10 of FIG. 3, taken along the line indicated therein.
FIG. 5 is a cross section of one of the nozzles 16 of the engine of FIG. 1 .
FIG. 6 is a schematic cross-sectional view of a tank useful in the present invention.
FIG. 7 is a schematic cross-sectional view of an impeller passage and an injector useful in the present invention.
DETAILED DESCRIPTION
FIG. 1 shows a schematic cross-section of an example embodiment of a rocket engine 8 according to the present invention.
The engine of FIG. 1 includes a rotor assembly comprising a rotor 10 , a spindle 12 , and a feed pipe 14 . The feed pipe 14 is fixed inside the center bore of a spool portion 52 of the spindle 12 , concentric with the axis of the spindle 12 , and extends outward from the spindle 12 beyond an end 38 of an extended portion 36 of the spindle 12 . The rotor assembly is supported on the extended portion 36 of the spindle 12 by bearings 48 in a bearing block 18 . Bearings 48 may be anti-friction bearings, or hydrodynamic fluid bearings may be used if desired. Seal 58 and retaining ring 60 mating with groove 62 cooperate with bearings 48 to support and retain the rotor assembly in the bearing block 18 . The feed pipe 14 is additionally supported by a bearing 54 in a fuel feed block 20 fixed to the bearing block 18 .
The rotor assembly defines, between an inner surface of the rotor 10 and an outer surface of the spool portion 52 of the spindle 12 , an annular combustion chamber 24 . The rotor 10 comprises nozzles 16 that each provide fluid communication from the combustion chamber 24 to the exterior of the engine 8 . The rotor 10 further comprises injectors 26 , in fluid communication with the combustion chamber 24 , for injecting propellant in the form of fuel and oxidizer into the combustion chamber 24 . The rotor 10 also comprises impeller passages 28 and 30 , in fluid communication with circumferential fluid passages 32 and 34 , respectively, in the spool portion 52 of the spindle 12 , and with the injectors 26 , for impelling fuel and oxidizer from the circumferential fluid passages 32 and 34 toward and through the injectors 26 .
The circumferential fluid passage 32 in the spool portion 52 of the spindle 12 is in fluid communication with the interior of the extended portion 36 of the spindle 12 via multiple bores extending radially inward from the circumferential fluid passage 32 , as shown in FIG. 2 (with one pair of the holes visible in cross-section). The interior surface of the extended portion 36 and the exterior surface of the feed pipe 14 together form an annular conduit for fuel from a fuel inlet 40 as shown in FIG. 1 . Seals 42 and 46 seal off a fuel inlet chamber 44 in fluid communication with the fuel inlet 40 and the annular conduit.
The circumferential fluid passage 34 in the spool portion 52 of the spindle 12 is in fluid communication with a center bore of the spool section 52 and, thereby, with the interior of the feed pipe 14 , via multiple bores extending radially inward from the circumferential fluid passage 34 . The interior of the feed pipe 14 is in fluid communication with an oxidizer inlet 56 formed in an oxidizer feed block 22 fixed to the fuel feed block 20 . The oxidizer inlet 56 is sealed from the exterior of the feed pipe 14 by a seal 58 .
The nozzles 16 in the rotor 10 are fixed within nozzle bores 64 shown in FIG. 3, which is an axial plan view of the rotor 10 of FIG. 1 . As shown in FIG. 3, the nozzle bores 64 communicate with the combustion chamber 24 at a point circumferantially offset and radially inward from the injectors 26 , and radially inward from the maximum radius 66 of the combustion chamber 24 . As shown in FIGS. 3 and 4, the nozzle bores 64 are not parallel with the axis of the rotor 10 , but are each tilted, in the circumferential direction, by an angle α (alpha) in the range of about 6 to about 12 degrees, depending upon the desired tangential velocity. An example De Laval nozzle shape for the nozzles 16 is shown in the cross section of FIG. 5 . Other types of nozzles may be employed as desired by those of skill in the art.
In operation of the engine of FIG. 1, the tilt of the nozzles 16 provides a tangential component to the primary thrust vectors, such that the rotor assembly rotates during operation of the engine, performing several functions thereby. The tilt angle and other relevant design parameters are selected such that this tangential component is sufficient to rotate the rotor assembly at high speed during operation of the engine, with tangential velocity desirably at least about 200 meters/second, most desirably at least 600 meters/second, at the greatest radius of the rotor assembly. As an alternative, such a tangential thrust component may also be provided by one or more vanes, flutes, or other reaction surfaces on or within an individual nozzle, if desired, such as in a cylindrical combustion chamber with a single nozzle, or in an annular combustion chamber with a spike nozzle, for example.
With the rotation of the rotor assembly, particularly at the relatively high speeds desired, the rotor assembly performs several useful functions.
As one function performed by the rotation of the rotor assembly, the impeller passages 28 and 30 in the rotor 10 (together with the radially inward bores 32 and 34 in the spool portion 52 of the spindle 12 ) act as a centrifugal pump to pressurize and deliver fuel and oxidizer to the injectors 26 . The surfaces that contain the fuel and oxidizer within the extended portion 36 of the spindle 12 (the inner surface of extended portion 36 and the outer and inner surfaces of feed tube 14 ) act to rotationally accelerate the liquid fuel and oxidizer, reducing the head required to prevent cavitation. In large engines, more or differently-shaped surfaces may be provided within the extended portion to act as inducers to avoid cavitation and to achieve adequate rotational and axial acceleration of the fuel and oxidizer.
As another function, these same passages also function as cooling passages, allowing heat from the combustion chamber 24 to be regeneratively transferred to the fuel and oxidizer by free and forced convection. As the fuel and oxidizer fluids are pumped radially outward through these passages, particularly at the relatively high speeds desirable in the present invention, the angular momentum of the fluids is increased sufficiently to result in a substantial Coriolis effect in these passages. The Coriolis effect increases the swirl in the passages and reduces the effective thickness of the boundary layer at the passage walls, increasing the cooling capacity beyond that achievable without the Coriolis effect. Optionally, at the inlet for the injectors 26 , structures may be imposed to capture some of the angular momentum of this swirl to increase pressurization. For example, the injector bore inlet may enter near the tangent of the impeller channel in opposition to the swirl to maximize the capture of swirl angular momentum for injector pressurization, as shown in FIG. 7 .
The centripetal acceleration of the fluid in the cooling/impeller passages is a primary driver of radial and therefore Coriolis flow but also itself tends to decrease the boundary layer and increase cooling capacity. Cryogenic liquid fuel and oxidizer are desirably used, providing high cooling capacity as the desired warming and pumping/pressurization of the cryogenic liquids is performed. Cryogenic temperatures further enhance mass ratio by strengthening otherwise desirable metals, such as aluminum, so that the rotary and static stresses on the rotor 10 can be contained with less mass.
Still another function of the rotating rotor assembly is to provide a rotating combustion chamber 24 . The rotating combustion chamber provides at least two particular advantages. First, nozzles 16 are positioned radially inwardly of feel injectors and from the widest radius of the combustion chamber, such that the centripetal acceleration of the rotating fluids in the chamber 24 tends to keep denser fluids, such as unburned and/or cold fuel or oxidizer, in the chamber longer, at the outer portion of the combustion chamber, so that more complete burning and higher I SP may be achieved. Second, because the injectors 26 are positioned radially outward from the nozzles 16 , fluids from the injectors must lose angular momentum in traveling from the injectors to the nozzles and out through the nozzles. This results in a Coriolis swirl effect in the combustion chamber, allowing better mixing and longer mixing of the oxidizer and propellant (and greater effective chamber length thereby enhancing mass ratio) for more complete combustion and higher I SP . The circumferential offset of the injectors from the nozzles, alone, also assists in providing better and longer mixing for more complete combustion and higher I SP . The thus-improved mixing and combustion is potentially less sensitive to injector design, allowing relaxed specification in this typically relatively critical component.
The rotor assembly thus acts as a self-driving pump and rotating combustion chamber, and the impellers or impeller passages of the pump(s) act as high fluid velocity vortex cooling passages for regenerative cooling. These several functions are performed by a single moving part, the rotor assembly, providing a simple and highly efficient method of pressurizing and pumping the fuel and oxidizer, allowing high injector pressures, desirably at least about 4500 psi (for lower density liquids like propane) and at least about 7500 psi (for higher density liquids like LOX) The high cooling capacity achieved in part through centripetal acceleration and the Coriolis effect in the cooling passages potentially allows use of unconventional materials for the combustion chamber and other rotor assembly parts, such as aluminum, (e.g., aluminum 7075-T6, a standard structural aluminum), which has good strength at extremes of low temperature, and excellent heat conduction. Highest performance applications would desirably employ high-strength composites to achieve maximum strength-to-weight ratios in the rotating components, particularly in those with the highest tangential velocities. Suitable composite materials, such as woven or spun carbon fiber in various forms, are known to those of skill in the art.
Liquid oxygen (LOX) and cooled liquid propane (LPG) are desirably employed as the oxidizer and fuel, respectively, in the propulsion system. Other thermally compatible fuel/oxidizer combinations may also be desirable, such LOX and liquid methane. Although LPG is liquid at higher temperatures than LOX, it may be maintained at the same temperature and pressure as LOX, eliminating the need for thermal insulation, simplifying tank design, and allowing both the fuel and the oxidizer to act as coolant fluids, rather than the oxidizer alone. LPG at LOX temperatures has negligible vapor pressure, increasing the available suction head at the LPG pump and thus reducing its tendency toward cavitation. The LOX and cooled LPG thus can both provide cryogenic coolant to the cooling passages surrounding the combustion chamber, providing a large thermal gradient and resultant good cooling capacity. Since both LOX and LPG can be used at the same temperature, no insulation is required in the engine (and pump) thus lightening, strengthening, and simplifying it. This allows a higher velocity and thus a higher developed pressure.
Other fuels are possible, for example, silane, ethane and methane are suitable for use with LOX. Other higher temperature oxidizers and fuels are possible, but they require the use of higher temperature materials, which materials have other tradeoffs, e.g. lower thermal conductivity. Variations of fuels and oxidizers necessitate corresponding temperature and pressure variations in tankage and engines, as understood in the art.
A desirable tank design is represented schematically in FIG. 6 . The dual tank 68 includes a LOX tank 70 with an outlet pipe 72 that passes concentrically through an LPG tank 74 . The feed pipe 72 has a first relatively large diameter except just before a coaxial outlet 78 , where the feed pipe 72 narrows. The LPG tank 74 is sealed around the outlet pipe 72 at the upper end, and has an opening surrounding and coaxial with the feed pipe 72 at coaxial outlet 78 . The use of LOX and LPG or other thermally compatible fuel and oxidizer combinations avoids the need for any insulation between the fuel and oxidizer, allowing the straightforward coaxial design. With the straight-down, coaxial outlet arrangement, acceleration of the propulsion system, in the direction upward in the figure, can directly and efficiently improve delivery of fuel and oxidizer from the tank.
The tank 68 is desirably formed of PET or other polymer material with good strength and flexibility, relative to its weight and cost, at cryogenic temperatures. Starting pressure in the tanks can be in the range of about 10 psi to about 160 psi, desirably about 30 psi, at temperatures in the range of about 90° K to about 111° K, desirably about 90° K.
The invention has been described herein with reference to particular embodiments, but variations within the spirit and scope of the invention will occur to those skilled in the art. For example, variations in materials, addition of supplemental systems such as ablative cooling, and other variations will occur to those of skill in the art. Accordingly, the scope of the invention is as defined in the appended claims.
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A simplified rocket engine a rocket engine has a rotor assembly with an ultracentrifugal (over 200 meters/second tangential velocity) liquid pump arranged around a combustion chamber so as to provide both forced convective and Coriolis-effect and centripetal-acceleration enhanced free convective regenerative cooling to the combustion chamber while pressurizing the liquid propellant. Both fuel and oxidizer may be stored a cryogenic temperatures and pumped around the combustion chamber for regenerative cooling. The combustion chamber may be structured to rotate together with the pump to provide Coriolis-effect and centripetal-acceleration enhanced combustion. The rotor assembly is driven directly by a tangential component of the primary thrust vector by means of tilted nozzles or by vanes, flutes, or other reaction surfaces. Liquid oxygen and liquid propane, maintained at about the same temperature and pressure, may be used as propellant and coolant, and may be stored in polyethylene terephthalate (PET) or other polymer tankage.
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This is a continuation-in-part of application Ser. No. 07/559,123 which was filed Jul. 27, 1990, now abandoned, which is a continuation-in-part application Ser. No. 419,226, filed Oct. 10, 1989, now abandoned, which is a continuation of application Ser. No. 264,918, filed Oct. 31, 1988 (now U.S. Pat. No. 4,876,250).
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to angiostatic steroids and their use in methods and compositions for controlling ocular hypertension. Specifically, the invention is directed to new angiostatic steroids, pharmaceutical compositions comprising the angiostatic steroids, and methods of treatment comprising administering these compositions to treat ocular hypertension, including controlling ocular hypertension associated with primary open angle glaucoma. In addition, the compounds can be used in combination with glucocorticoids to control the ocular hypertension very commonly associated with the use of glucocorticoids in the treatment of ocular inflammation.
2. Description of Related Art
Steroids functioning to inhibit angiogenesis in the presence of heparin or specific heparin fragments are disclosed in Crum, et al., A New Class of Steroids Inhibits Angiogenesis in the Presence of Heparin or a Heparin Fragment, Science, Vol.230, pp.1375-1378 (Dec. 20, 1985). The authors refer to such steroids as "angiostatic" steroids. Included within the new class of steroids found to be angiostatic are the dihydro and tetrahydro metabolites of cortisol and cortexolone. In a follow-up study directed to testing a hypothesis as to the mechanism by which the steroids inhibit angiogenesis, it was shown that heparin/angiostatic steroid compositions cause dissolution of the basement membrane scaffolding to which anchorage dependent endothelia are attached resulting in capillary involution; see, Ingber, et al., A Possible Mechanism for Inhibition of Angiogenesis by Angiostatic Steroids: Induction of Capillary Basement Membrane Dissolution, Endocrinology 119, pp.1768-1775 1986).
A group of tetrahydro steroids useful in inhibiting angiogenesis is disclosed in International Patent Application No. PCT/US86/02189, Aristoff, et al., (The Upjohn Company). The compounds are disclosed for use in treating head trauma, spinal trauma, septic or traumatic shock, stroke and hemorrhage shock. In addition, the patent application discusses the utility of these compounds in embryo implantation and in the treatment of cancer, arthritis and arteriosclerosis. The compounds are not disclosed for ophthalmic use.
Tetrahydrocortisol (THF) has been disclosed for its use in lowering the intraocular pressure (IOP) of rabbits made hypertensive with dexamethasone alone, or with dexamethasone/5-beta-dihydrocortisol; see Southren, et al., Intraocular Hypotensive Effect of a Topically Applied Cortisol Metabolite: 3-alpha, 5-beta-tetrahydrocortisol, Investigative Ophthalmology and Visual Science, Vol.28 (May, 1987). The authors suggest THF may be useful as an antiglaucoma agent. In U.S. Pat. No. 4,863,912, issued to Southren et al. on Sep. 5, 1989, pharmaceutical compositions containing THF and a method for using these compositions to control intraocular pressure are disclosed. THF has been disclosed as an angiostatic steroid in Folkman, et al., Angiostatic Steroids, Ann. Surg., Vol.206, No. 3 (1987) wherein it is suggested angiostatic steroids may have potential use for diseases dominated by abnormal neovascularization, including diabetic retinopathy, neovascular glaucoma and retrolental fibroplasia.
Many compounds classified as glucocorticoids, such as dexamethasone and prednisolone, are very effective in the treatment of inflammed tissues. When applied topically to the eye to treat ocular inflammation, these compounds cause elevations in intraocular pressure in certain patients. Patients who experience these elevations when treated with glucocorticoids are generally referred to as "steroid responders". The elevations are of particular concern in patients already suffering from elevated intraocular pressures, such as glaucoma patients. In addition, there is always a risk that the use of glucocorticoids in patients with normal intraocular pressures will cause pressure elevations resulting in damage to ocular tissue. Since glucocorticoid therapy is frequently long term (i.e., several days or more), there is potential for significant damage to ocular tissue as a result of prolonged elevations in intraocular pressure attributable to that therapy. Commonly assigned U.S. application Ser. No. 399,351 discloses the use of the angiostatic steroid tetrahydrocortexolone, in combination with a glucocorticoid to prevent the intraocular pressure elevating effect of the glucocorticoid being used in the treatment of ophthalmic inflammation.
SUMMARY OF THE INVENTION
This invention is directed to steroids useful in inhibiting angiogenesis. The compounds can be used for treatment of, for example, head trauma, spinal trauma, septic or traumatic shock, stroke, hemorrhage shock, cancer, arthritis, and arteriosclerosis. In particular, the angiostatic steroids and compositions thereof are useful for controlling ocular hypertension. The compositions are particularly useful in the treatment of primary open angle glaucoma.
The invention encompasses methods for controlling ocular hypertension through the topical administration of the compositions disclosed herein.
Moreover, the invention includes the use of the angiostatic steroids in combination with a glucocorticoid being used to treat ocular inflammation. The angiostatic steroid makes it possible to employ the potent antiinflammatory glucocorticoids without producing significant elevations in intraocular pressure.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The development of blood vessels for the purpose of sustaining viable tissue is known as angiogenesis. Agents which inhibit angiogenesis are known by a variety of terms such as angiostatic, angiolytic or angiotropic agents. For purposes of this specification, the term "angiostatic agent" means compounds which can be used to inhibit angiogenesis.
The angiostatic agents of the present invention are steroids or steroid metabolites. For purposes herein, the term "angiostatic steroids" means steroids and steroid metabolites which inhibit angiogenesis. The present invention is based on the finding that angiostatic steroids can be used for the control of ocular hypertension. In particular, the agents can be used for the treatment of primary open angle glaucoma.
The angiostatic steroids of the present invention have the following formula: ##STR1## wherein R 1 is H, β-CH 3 or β-C 2 H 5 ;
R 2 is F, C 9 -C 11 double bond, C 9 -C 11 epoxy, H or Cl;
R 3 is H, OR 26 , OC(═O)R 27 , halogen, C 9 -C 11 double bond, C 9 -C 11 epoxy, ═O, --OH, --O--alkyl(C 1 -C 12 ), --OC(═O)alkyl(C 1 -C 12 ), --OC(═O)ARYL, --OC(═O)N(R) 2 or --OC(═O)OR 7 , wherein ARYL is furyl, thienyl, pyrrolyl, or pyridyl and each of said moieties is optionally substituted with one or two (C 1 -C 4 )alkyl groups, or ARYL is --(CH 2 ) f --phenyl wherein f is 0 to 2 and the phenyl ring is optionally substituted with 1 to 3 groups selected from chlorine, fluorine, bromine, alkyl(C 1 -C 3 ), alkoxy(C 1 -C 3 ), thioalkoxy-(C 1 -C 3 ), Cl 3 C--, F 3 C--, --NH 2 and --NHCOCH 3 and R is hydrogen, alkyl (C 1 -C 4 ), or phenyl and each R can be the same or different, and R 7 is ARYL as herein defined, or alkyl (C.sub. 1 -C 12 );
R 4 is H, CH 3 , Cl or F;
R 5 is H, OH, F, Cl, Br, CH 3 , phenyl, vinyl or allyl;
R 6 is H or CH 3 ;
R 9 is CH 2 CH 2 OR 26 , CH 2 CH 2 OC(═O)R 27 , H, OH, CH 3 , F, ═CH 2 , CH 2 C(═O)OR 28 , OR 26 , O(C═O))R 27 or O(C═O)CH 2 (C═O)OR 26
R 10 is --CH.tbd.CH, --CH═CH 2 , halogen, CN, N 3 , OR 26 , OC(═O)R 27 , H, OH, CH 3 or R 10 forms a second bond between positions C-16 and C-17;
R 12 is H or forms a double bond with R 1 or R 14 ;
R 13 is halogen, OR 26 , OC(═O)R 27 , NH 2 , NHR 26 , NHC(═O)R 27 , N(R 26 ) 2 , NC(═O)R 27 , N 3 , H, --OH, ═O, --O--P(═O)(OH) 2 , or --O--C(═O)--(CH 2 ) t COOH where t is an integer from 2 to 6;
R 14 is H or forms a double bond with R 12 ;
R 15 is H, ═O or --OH; and R 23 with R 10 forms a cyclic phosphate;
wherein R 9 and R 15 have the meaning defined above; or wherein R 23 is --OH, O--C(═O)--R 11 , --OP(O)--(OH) 2 , or --O--C(═O)--(CH 2 ) t COOH
wherein t is an integer from 2 to 6; and R 11 is --Y--(CH 2 ) n --X--(CH 2 ) m --SO 3 H,--Y'--(CH 2 ) p --X'--(CH 2 ) q --NR 16 R 17 or --Z(CH 2 ) r Q,
wherein Y is a bond or --O--; Y' is a bond, --O--, or --S--; each of X and X' is a bond, --CON(R 18 )--, --N(R 18 )CO--, --O--, --S--, --S(O)--, or --S(O 2 )--; R 18 is hydrogen or alkyl (C 1 -C 4 ); each of R 16 and R 17 is a lower alkyl group of from 1 to 4 carbon atoms optionally substituted with one hydroxyl or R 16 and R 17 taken together with the nitrogen atom to which each is attached forms a monocyclic heterocycle selected from pyrrolidino, piperidino, morpholino, thiomorpholino, piperazino or N(lower)alkyl-piperazino wherein alkyl has from 1 to 4 carbon atoms; n is an integer of from 4 to 9; m is an integer of from 1 to 5; p is an integer of from 2 to 9; q is an integer of from 1 to 5;
Z is a bond or --O--; r is an integer of from 2 to 9; and Q is one of the following:
(1) --R 19 --CH 2 COOH wherein R 19 is --S--, --S(O)--, --S(O) 2 --, --SO 2 N(R 20 ) --, or N(R 20 )SO 2 13 ; and R 20 is hydrogen or lower alkyl--(C 1 -C 4 ); with the proviso that the total number of carbon atoms in R 20 and (CH 2 )is not greater than 10; or
(2 ) --CO--COOH; or
(3) CON(R 21 )CH(R 22 )COOH wherein R 21 is H and R 22 is H, CH 3 , --CH 2 COOH, --CH 2 CH 2 COOH, --CH 2 OH, --CH 2 SH, --CH 2 CH 2 SCH 3 , or --CH 2 Ph--OH wherein Ph--OH is p-hydroxyphenyl;
or R 21 is CH 3 and R 22 is H;
or R 21 and R 22 taken together are 13 CH 2 CH 2 CH 2 --;
or --N(R 21 )CH(R 22 )COOH taken together is --NHCH 2 CONHCH 2 COOH; and pharmaceutically acceptable salts thereof;
with the proviso that except for the compound wherein R 1 is β-CH 3 , R 2 and R 3 taken together form a double bond between positions 9 and 11, R 4 and R 6 are hydrogen, R 12 and R 14 taken together form a double bond between positions 4 and 5, R 5 is α-F, R 9 is β-CH 3 , R 10 is α-OH, R 13 and R 15 are ═O and R 23 is --OP(O)--(OH) 2 , R 13 is ═O only when R 23 with R 10 forms the above described cyclic phosphate.
R 24 =C, C 1 -C 2 double bond, O;
R 25 =C(R 15 )CH 2 --R 23 , OH, OR 26 , OC(═O)R 27 , R 26 , COOH, C(═O)OR 26 , CHOHCH 2 OH, CHOHCH 2 OR 26 , CHOHCH 2 OC(═O)R 27 , CH 2 CH 2 OH, CH 2 CH 2 OR 26 , CH 2 CH 2 OC(═O)R 27 , CH 2 CN, CH 2 N 3 , CH 2 NH 2 , CH 2 NHR 26 , CH 2 N(R 26 ) 2 , CH 2 OH, CH 2 OR 26 , CH 2 O(C═O)R 27 , CH 2 O(P═O) (OH) 2 , CH 2 O(P═O) (OR 26 ) 2 , CH 2 SH, CH 2 S--R 26 , CH 2 SC(═O)R 27 , CH 2 NC(═O)R 27 , C(═O)CHR 28 OH, C(═O)CHR 28 OR 26 , C(═O)CHR 28 OC(═O)R 27 or R 10 and R 25 taken together may be ═C(R 28 ) 2 , that is, an optionally alkyl substituted methylene group;
wherein R 26 =C 1 14 C 6 (alkyl, branched alkyl, cycloalkyl, haloalkyl, aralkyl, aryl); R 27 =R 26 +OR 26 ; R 28 =H, C1-C6 (alkyl, branched alkyl, cycloalkyl).
Excepted from the compounds of Structure [A] are the compounds wherein R 1 is β-CH 3 or β-C 2 H 5 ;
R 2 is H or Cl;
R 3 is H, ═O, --OH, --O--alkyl(C 1 -C 12 ), --OC(═O)alkyl (C 1 -C 12 ), --OC(═O)ARYL, --OC(═O)N(R) 2 or α-OC(═O)OR 7 , wherein ARYL is furyl, thienyl, pyrrolyl, or pyridyl and each of said moieties is optionally substituted with one or two (C 1 -C 4 )alkyl groups, or ARYL is --(CH 2 ) f -phenyl wherein f is 0 to 2 and the phenyl ring is optionally substituted with 1 to 3 groups selected from chlorine, fluorine, bromine, alkyl(C 1 -C 3 ), alkoxy(C 1 -C 3 ), thioalkoxy-(C 1 -C 3 ), Cl 3 C--, F 3 C--, --NH 2 and --NHCOCH 3 and R is hydrogen, alkyl (C 1 -C 4 ), or phenyl and each R can be the same or different, and R 7 is ARYL as herein defined, or alkyl (C 1 -C 12 ); or
wherein R 2 and R 3 taken together are oxygen (--O--) bridging positions C-9 and C-11; or
wherein R 2 and R 3 taken together form a double bond between positions C-9 and C-11;
or R 2 is α-F and R 3 is β--OH;
or R 2 is α-Cl and R 3 is β--Cl;
and R 4 is H, CH 3 , Cl or F;
R 5 is H, OH, F, Cl, Br, CH 3 , phenyl, vinyl or allyl;
R 6 is H or CH 3 ;
R 9 is H, OH, CH 3 , F or ═CH 2 ;
R 10 is H, OH, CH 3 or R 10 forms a second bond between positions C-16 and C17;
R 12 is --H or forms a double bond with R 14 ;
R 13 is H, --OH, ═O, --O--P(O)(OH) 2 , or --O--C(═O)--(CH 2 ) t COOH where t is an integer from 2 to 6;
R 14 is H or forms a double bond with R 12 ;
R 15 is ═Oor --OH; and R 23 with R 10 forms a cyclic phosphate;
wherein R 9 and R 15 have the meaning defined above; or wherein R 23 is --OH, O--C(═O)--R 11 , --OP(O)--(OH) 2 , or --O--C(═O)--(CH 2 ) t COOH
wherein t is an integer from 2 to 6: and R 11 is --Y--(CH 2 ) n --X--(CH 2 ) m --SO 3 H,--Y'--(CH 2 ) p --X'--(CH 2 ) q --NR 16 R 17 or --Z(CH 2 ) r Q, wherein Y is a bond, or --O--; Y' is a bond, --O--, or --S--; each of X and X' is a bond,--CON(R 18 )--, --N(R 18 )CO--, --O--, --S--, --S(O)--, or --S(O 2 )--; R 18 is hydrogen or alkyl (C 1 -C 4 ); each of R 16 and R 17 is a lower alkyl group of from 1 to 4 carbon atoms optionally substituted with one hydroxyl or R 16 and R 17 taken together with the nitrogen atom to which each is attached forms a monocyclic heterocycle selected from pyrrolidino, piperidino, morpholino, thiomorpholino, piperazino or N(lower)alkyl-piperazino wherein alkyl has from 1 to 4 carbon atoms; n is an integer of from 4 to 9; m is an integer of from 1 to 5; p is an integer of from 2 to 9; q is an integer of from 1 to 5; Z is a bond or --O--; r is an integer of from 2 to 9; and Q is one of the following:
(1) --R 19 --CH 2 COOH wherein R 19 is --S--, --S(O)--, --S(O) 2 --, --SO 2 N(R 20 )--, or N(R 20 )SO 2 --; and R 20 is hydrogen or lower alkyl-(C 1 -C 4 ); with the proviso that the total number of carbon atoms in R 20 and (CH 2 ) r is not greater than 10; or
(2) --CO--COOH; or
(3) CON(R 21 )CH(R 22 )COOH wherein R 21 is H and R 22 is H, CH 3 , --CH 2 COOH, --CH 2 CH 2 COOH, --CH 2 OH, --CH 2 SH, --CH 2 CH 2 SCH 3 , or --CH 2 Ph--OH wherein Ph--OH is p-hydroxyphenyl;
or R 21 is CH 3 and R 22 is H;
or R 21 and R 22 taken together are 13 CH 2 CH 2 CH 2 --;
or --N(R 21 )CH(R 22 )COOH taken together is --NHCH 2 CONHCH 2 COOH; and pharmaceutically acceptable salts thereof;
with the proviso that except for the compound wherein R 1 is β-CH 3 , R 2 and R 3 taken together form a double bond between positions 9 and 11, R 4 and R 6 are hydrogen, R 12 and R 14 taken together form a double bond between positions 4 and 5, R 5 is α-F, R 9 is β-CH 3 , R 10 is α-OH, R 13 and R 15 are ═O and R 23 is --OP(O)--(OH) 2 , R 13 is ═O only when R 23 with R 10 forms the above described cyclic phosphate.
Also excepted from the compounds of Structure [A] are the compound 3,11β, 17α, 21-tetrahydroxy-5-pregnane-20-one (the 3-α, 5-β; 3-α, 5α; 3-β; 5-α; and 3-β, 5-β isomers of tetrahydrocortisol) wherein R 15 is ═O, R 10 is α-OH, R 1 is β-CH 3 , R 3 is β-OH, R 2 is H, R 4 is H, R 13 is α- or β-OH, R 14 is H, R 12 is α- or β-H, R 5 is H, R 6 is H, R 9 is H, R 24 is C, and R 23 is OH; and methyltestosterone, wherein R 1 is β-CH 3 , R 2 is H, R 3 is H, R 4 is H, R 5 is H, R 6 is H, R 9 is H, R 10 is α-CH 3 , R 12 and R.sub. 14 form a C 4 -C 5 double bond, R 13 is ═O, R 24 is C and R 25 is β-OH; dihydrotestosterone, wherein R 1 is β-CH 3 , R 2 R 3 R 4 R 5 R 6 R 9 R 10 R 14 are H, R 12 is α-H, R 13 is ═O, R 24 is β-OH; dromostanolone propionate, wherein R 1 is β-CH 3 , R 2 R 3 R 4 R 5 R 6 R 9 R 10 R 14 are H, R 12 is α-H, R 13 is ═O, R 24 is C and R 25 is β-OC(═O)CH 2 CH 3 ; methandrostenelone, wherein R 1 is β-CH 3 , R 2 R 3 R 4 R 5 R 6 R 9 are H, R 10 is α-CH 3 , R 12 and R 14 form a C 4 C 5 double bond, R 13 is ═O, R 24 is C 1 C 2 double bond, and R 25 is β-OH; testosterone, wherein R 1 is β-CH 3 , R 2 R 3 R 4 R 5 R 6 R 9 R 10 are H, R 12 and R 14 form a C 4 C 5 double bond, R 13 is ═O, R 24 is C, and R 25 is β-OH; norethandrolone, wherein R 1 is CH 3 (C 13 ) and H(C 10 ), R 2 R 3 R 4 R 5 R 6 R 9 are H, R 10 is α-CH 2 CH 3 , R 12 and R 14 form a C 4 14 C 5 double bond, R 13 is ═O, R 24 is C, and R 25 is β-OH; bolasterone, wherein R 1 is β-CH 3 , R 2 R 3 R 4 R 5 R 9 are H, R 6 is α-CH 3 , R 10 is α-CH 3 , R 13 is ═O, R 12 and R 14 form a C 4 C 5 double bond, C 24 is C and R 25 is β-OH; and oxandrolone, wherein R 1 is β-CH 3 , R 2 R 3 R 5 R 6 R 9 R 14 are H, R 10 is α-CH 3 , R 12 is α-H, R 13 is ═O, R 24 , is O, and R 25 is β-OH.
Unless specified otherwise, all substituent groups attached to the cyclopentanophenanthrene moiety of Structures [A] and [B] may be in either the alpha or beta position. Additionally, the above structures include all pharmaceutically acceptable salts of the angiostatic steroids.
Preferred angiostatic steroids are ##STR2##
MOST PREFERRED ANGIOSTATIC STEROID ##STR3##
The more preferred compounds are 21-methyl-5β-pregnan-3α, 11β, 17α,21-tetrol 20-one-21-methyl ether; 3β-azido-21-acetoxy-5β-pregnan-11β, 17α-diol-20-one; 3β-acetamido-21-acetoxy-5β-pregnan-11β, 17α-diol-20-one; and 5β-pregnan-11β, 17α, 21-triol-20-one. The most preferred compound is 4,9(11)-pregnadien-17α,21-diol -3,20-dione-21-acetate.
Without intending to be bound by any theory, it is believed that the angiostatic steroids of the type described above act to control intraocular pressure by inhibiting the accumulation or stimulating the dissolution of amorphous extracellular material in the trabecular meshwork of the eye. The presence of this amorphous extracellular material alters the integrity of the healthy trabecular meshwork and is a symptom associated with primary open angle glaucoma (POAG). It is not well understood why this amorphous extracellular material builds up in the trabecular meshwork of persons suffering from POAG. However, it has been found that the amorphous extracellular material is generally composed of glycosaminoglycans (GAGs) and basement membrane material; see, Ophthalmology, Vol.90, No.7 (July 1983); Mayo Clin. Proc, vol.61, pp.59-67 (January 1986); and Pediat. Neurosci. Vol.12, pp.240-251 (1985-86). When these materials build up in the trabecular meshwork, the aqueous humor, normally present in the anterior chamber of the eye, cannot leave this chamber through its normal route (the trabecular meshwork) at its normal rate. Therefore, a normal volume of aqueous humor is produced by the ciliary processes of the eye and introduced into the anterior chamber, but its exit through the trabecular meshwork is abnormally slow. This results in a buildup of pressure in the eye, ocular hypertension, which can translate into pressure on the optic nerve. The ocular hypertension so generated can lead to blindness due to damage to the optic nerve.
Many methods for treating primary open angle glaucoma and ocular hypertension concentrate on blocking production of aqueous humor by the eye. However, aqueous humor is the fundamental source of nourishment for the tissues of the eye, particularly the cornea and lens which are not sustained by blood supply. Therefore, it is not desirable to deprive these tissues of the necessary irrigation and nutrition provided by the aqueous humor. It is desirable to strive for normal exit of the aqueous humor by maintaining the normal integrity of the trabecular meshwork. This is accomplished according to the present invention by the administration of angiostatic steroids.
It is believed that the angiostatic steroids disclosed herein function in the trabecular meshwork in a similar manner as shown by Ingber, et al., wherein it was shown that angiostatic steroids caused dissolution of the basement membrane scaffolding using a chick embryo neovascularization model; Endocrinology, 119, pp.1768-1775 (1986). It is believed that the angiostatic steroids of the present invention prevent the accumulation, or promote the dissolution of, amorphous extracellular materials in the trabecular meshwork by inhibiting the formation of basement membrane materials and glycosaminoglycans. Thus, by preventing the development of these materials or promoting their dissolution, the normal integrity of the trabecular meshwork is retained and aqueous humor may flow through the trabecular meshwork at normal rates. As a result, the intraocular pressure of the eye is controlled.
The angiostatic steroids of the present invention may be incorporated in various formulations for delivery to the eye. For example, topical formulations can be used and can include ophthalmologically acceptable preservatives, surfactants, viscosity enhancers, buffers, sodium chloride and water to form aqueous sterile ophthalmic solutions and suspensions. In order to prepare sterile ophthalmic ointment formulations, an angiostatic steroid is combined with a preservative in an appropriate vehicle, such as mineral oil, liquid lanolin or white petrolatum. Sterile ophthalmic gel formulations comprising the angiostatic steroids of the present invention can be prepared by suspending an angiostatic steroid in a hydrophilic base prepared from a combination of, for example, Carbopol-940 (a carboxyvinyl polymer available from the B. F. Goodrich Company) according to published formulations for analogous ophthalmic preparations. Preservatives and tonicity agents may also be incorporated in such gel formulations.
The specific type of formulations selected will depend on various factors, such as the angiostatic steroid or its salt being used, and the dosage frequency. Topical ophthalmic aqueous solutions, suspensions, ointments and gels are the preferred dosage forms. The angiostatic steroid will normally be contained in these formulations in an amount of from about 0.005 to about 5.0 weight percent (wt. %). Preferable concentrations range from about 0.05 to about 2.0wt. %. Thus, for topical administration, these formulations are delivered to the surface of the eye one to four times per day, depending upon the routine discretion of the skilled clinician.
In addition, antiinflammatory compositions of glucocorticoids can contain one or more angiostatic steroids of the present invention. These compositions will contain one or more glucocorticoids in an antiinflammatory effective amount and will contain one or more angiostatic steroids of the present invention in an amount effective to inhibit the IOP elevating effect of the glucocorticoids. The amount of each component will depend on various factors, such as the relative tendency of certain glucocorticoids to cause IOP elevations, the severity and type of ocular inflammation being treated, the estimated duration of the treatment, and so on. In general, the ratio of the amount of glucocorticoid to the amount of angiostatic steroid on a weight to weight basis will be in the range of 10:1 to 1:20. The concentration of the glucocorticoid component will typically be in the range of about 0.01% to about 2.0% by weight. The concentration of the angiostatic steroid component will typically be in the range of about 0.05% to about 5.0% by weight.
The following examples illustrate formulations and synthesis of compounds of the present invention, but are in no way limiting.
EXAMPLE 1
______________________________________Component wt. %______________________________________Angiostatic Steroid 0.005-5.0Tyloxapol 0.01-0.05HPMC 0.5Benzalkonium Chloride 0.01Sodium Chloride 0.8Edetate Disodium 0.01NaOH/HCl q.s. pH 7.4Purified Water q.s. 100 mL______________________________________
EXAMPLE 2
______________________________________Component wt. %______________________________________21-methyl-5β-pregnan-3α, 11β, 1.017α, 21-tetrol-20-one 21-methyl etherTyloxapol 0.01-0.05HPMC 0.5Benzalkonium Chloride 0.01Sodium Chloride 0.8Edetate Disodium 0.01NaOH/HCl q.s. pH 7.4Purified Water q.s. 100 mL______________________________________
The above formulation is prepared by first placing a portion of the purified water into a beaker and heating to 90° C. The hydroxypropylmethylcellulose (HPMC) is then added to the heated water and mixed by means of vigorous vortex stirring until all of the HPMC is dispersed. The resulting mixture is then allowed to cool while undergoing mixing in order to hydrate the HPMC. The resulting solution is then sterilized by means of autoclaving in a vessel having a liquid inlet and a hydrophobic, sterile air vent filter.
The sodium chloride and the edetate disodium are then added to a second portion of the purified water and dissolved. The benzalkonium chloride is then added to the solution, and the pH of the solution is adjusted to 7.4 with 0.1M NaOH/HCl. The solution is then sterilized by means of filtration.
The 21α-methyl-5β-pregnan-3α, 11β, 17α, 21-tetrol-20-one 21 methyl ether is sterilized by either dry heat or ethylene oxide. If ethylene oxide sterilization is selected, aeration for at least 72 hours at 50° C. is necessary. The sterilized steroid is weighed aseptically and placed into a pressurized ballmill container. The tyloxapol, in sterilized aqueous solution form, is then added to the ballmill container. Sterilized glass balls are then added to the container and the contents of the container are milled aseptically at 225 rpm for 16 hours, or until all particles are in the range of approximately 5 microns.
Under aseptic conditions, the micronized drug suspension formed by means of the preceding step is then poured into the HPMC solution with mixing. The ballmill container and balls contained therein are then rinsed with a portion of the solution containing the sodium chloride, the edetate disodium and benzalkonium chloride. The rinse is then added aseptically to the HPMC solution. The final volume of the solution is then adjusted with purified water and, if necessary, the pH of the solution is adjusted to pH 7.4 with NaOH/HCl.
EXAMPLE 3
The following formulation is representative of the antiinflammatory compositions of the present invention.
______________________________________Component wt. %______________________________________4,9(11)pregnadien-17α, 21-diol-3, 20- 1.0dione-21-acetateDexamethasone 0.1Tyloxapol 0.01 to 0.05HPMC 0.5Benzalkonium Chloride 0.01Sodium Chloride 0.8Edetate Disodium 0.01NaOH/HCl q.s. pH 7.4Purified Water q.s. 100 mL______________________________________
The above formulation is prepared in the same manner set forth in Example 2, sterilizing and adding the dexamethasone to the steroid before placing both into a pressurized ballmill container.
EXAMPLE 4
Preparation of 5β-Pregnan-11β, 17α, 21-Triol-20-one
Tetrahydrocortisol-F-21-t-butyldiphenylsilyl ether (PS03842)
A solution of 4.75 g (17.3 mmol) of t-butyldiphenylchlorosilane in 5 mL of dry DMF was added dropwise to a stirred solution of 5.7 g (15.6 mmol) of tetrahydrocortisol-F (Steraloids No. P9050) and 2.3 g (19 mmol) of 4-dimethylaminopyridine (DMAP) in 30 mL of dry DMF, under N 2 , at -25° to -30° C., (maintained with CO 2 -MeCN). After a further 20 min at -30° C., the mixture was allowed to warm to 23° C. overnight.
The mixture was partitioned between ether and water, and the organic solution was washed with brine, dried (MgSO 4 ), filtered and concentrated to give 10.7 g of a white foam.
This material was purified by flash column chromatography (400 g silica; 62.5 to 70% ether/hexane). The 3-siloxy isomer eluted first, followed by mixed fractions, followed by the title compound. The concentrated mixed fractions (4.0 g) were chromatographed on the same column with 35% ethyl acetate/hexane. The total yield of the 3-siloxy isomer was 0.42 g (5%), and of the title compound, 5.05 g (53.5%). Continued elution with 25% MeOH/EtOAc allowed recovery of unreacted tetrahydrocortisol-F.
PS03842
NMR (200 MHz 1 H) (CDCl 3 ): δ0.63 (s, 3H, Me-18); 1.11 (s, 9H, t-Bu); 1.12 (s, 3H, Me-19); 2.57 (t, J=13, 1H, H-8); 2.6 (s, 1H, OH-17); 3.63 (sept, J=2.5, 1H, H-3); 4.15 (br s, 1H, H-11); 4.37 and 4.75 (AB, J=20, 2H, H-21); 7.4 (m, 6H) and 7.7 (m, 4H) (Ph 2 ).
NMR (200 MHz 1 H) (DMSO-d 6 ): δ0.64 (s, 3H, Me-18); 1.02 (s, 9H, t-Bu); 1.07 (s, 3H, Me-19); 2.50 (t, J=13, 1H, H-8); 3.37 (m, 1H, H-3); 3.94 (d, J=2, 1H, OH--11); 4.00 (br s, 1H, H-11); 4.42 (d, J=5, 1H, OH-3); 4.38 and 4.83 (AB, J=20, 2H, H-21); 5.11 (s, 1H, OH-17); 7.45 (m, 6H) and 7.6 (m, 4H) (Ph 2 ).
NMR (50.3- MHz 13 C) (CDCl 3 ): 17.4 (C-18); 19.3 (C-16); 23.7 (C-15); 26.3 (C-7); 26.6 (C-19); 26.8 (Me 3 C); 27.2 (C-6); 30.9 (C-2); 31.5 (C-8); 34.1(Me 3 C); 34.8 (C-10); 35.2 (C-1); 36.2 (C-4); 39.7 (C-13); 43.5 (C-5); 44.3 (C-9); 47.4 (C-12); 52.1 (C-14); 67.8 (C-11); 68.9 (C-21); 71.7 (C-3); 89.8 (C-14); 127.8, 129.8, 132.8, 132.9, 135.7, 135.8 (diastereotopic Ph 2 ); 208.8 (C-20). Underlined resonances showed inversion in the APT experiment. Assignments: E. Breitmaier, W. Voelter "Carbon-13 NMR Spectroscopy," 3d ed., VCH, 1987; pp. 345-348.
IR (KBr) 3460, 2930, 2860, 1720, 1428, 1136, 1113, 1070, 1039, 703 cm -1 .
This compound did not show a sharp melting point but turned to a foam at 80°-100° C. Numerous attempts at recrystallization failed.
5β-Pregnan-11β, 17α, 21-triol-20-one
A solution of PS03842 (0.91 g, 1.50 mmol) and thiocarbonyl diimidazole (1.05 g, 5.9 mmol) in 8 mL of anhydrous dioxane was refluxed under N 2 for 3.5 h. The cooled solution was partitioned between ether and water and the organic solution was washed with brine, dried (MgSO 4 ), filtered and concentrated. The residue was chromatographed (120 g SiO 2 , 35% EtOAc/hexane) giving 0.86 g (80%) of the imidazolyl thioester.
A solution of 0.75 g (1.05 mmol) of this compound in 100 mL of anhydrous dioxane was added dropwise over 2.2 h to a rapidly stirred, refluxing solution of 1.6 mL (5.9 mmol) of Bu 3 SnH in 100 mL of anhydrous dioxane under N 2 . After a further 1 h at reflux, the solution was cooled, concentrated and the residue chromatographed (200 g SiO 2 , 9% EtOAc/hexane) giving 0.43 g (70%) of the 3-deoxy-21-silyl ether. This material was dissolved in 20 mL of methanol; Bu 4 NF·3H 2 O (0.50 g, 1.6 mmol) was added, and the mixture was heated to reflux under N 2 for 4 h. The cooled solution was diluted with 2 volumes of EtOAc, concentrated to 1/4 volume, partitioned (EtOAc/H 2 O), and the organic solution was washed with brine, dried (MgSO 4 ), filtered and concentrated. The residue (0.40 g) was chromatographed (30 g SiO.sub. 2, 40% EtOAc/hexane) to give 0.25 g (98%) of an oil.
This oil was crystallized (n-BuCl) to afford 0.14 g of the title compound as a white solid, m.p. 167°-170° C.
IR (KBr): 3413 (br), 2934, 1714, 1455, 1389, 1095, 1035 cm -1 .
MS (CI): 351 (M+1).
NMR (200 MHz 1 H, DMSO-d 6 ): δ0.69 (s, 3H, Me-18); 1.14 (s, 3H, Me-19); 0.8-2.0 (m); 2.5 (t, J=13, 1H, H-8); 3.96 (d, J=2, 1H, OH-11); 4.1 (br s, 1H, H-11); 4.1 and 4.5 (AB, further split by 5 Hz, 2H, H-21); 4.6 (t, J=5, 1H, OH-21); 5.14 (s, 1H, OH-17).
Anal. Calc'd for C 21 H 34 O 4 : C, 71.96; H, 9.78. Found: C, 71.69; H, 9.66.
EXAMPLE 5
Preparation of 21-Methyl-5β-pregnan-3α, 11β, 17α, 21-tetrol-20-one 21-methyl ether
Sodium hydride (60% oil dispersion, 0.10 g, 2.5 mmol) was added to a stirred solution of tetrahydrocortisol-F (0.73 g, 2.0 mmol) and CH 3 I (0.60 mL, 9.6 mmol) in 8 mL of anhydrous DMF under N 2 . Hydrogen was evolved, and the temperature rose to 35° C. After 1 h, the mixture was diluted with EtOAc, extracted with water (until neutral) and brine, dried (MgSO 4 ), filtered and concentrated. The residue was chromatographed (70 g SiO 2 , 80% EtOAc/hexane) to give 0.17 g of a white solid, MS (CI)=395 (M+1). This material was recrystallized (EtOAc-n-BuCl) to afford 0.12 g (16%) of the title compound as a feathery white solid, m.p. 208°-213° C.
IR (KBr): 3530, 3452, 2939, 2868, 1696 (s, CO), 1456, 1366, 1049 cm -1 .
NMR (200 MHz 1 H, DMSO-d 6 ): δ0.74 (s, 3H, Me-18); 1.09 (s, 3H, Me-19); 1.14 (d, J=6.6, 3H, C-21 Me); 0.8-2.0 (m); 2.47 (t, J=13, 1H, H-8); 3.18 (s, 3H, OMe); 3.35 (m, 1H, H-3); 4.00 (d, J=2, 1H, OH-11); 4.07 (br s, 1H, H-11); 4.37 (q, J=6.6, 1H, H-21); 4.43 (d, J=5, 1H, OH-3); 5.16 (s, 1H, OH-17).
Anal. Calc'd for C 23 H 38 O 5 : C, 70.01; H, 9.71. Found: C, 70.06; H, 9.76.
EXAMPLE 6
Preparation of 3β-Azido-21-acetoxy-5β-pregnan-11β, 17α-diol-20-one
A solution of triphenylphosphine (2.6 g, 10 mmol) in 10 mL of toluene was carefully added to a stirred solution of PS03842 (see Example 4) (1.75 g, 2.90 mmol), diphenylphosphoryl azide (2.2 mL, 10.2 mmol) and diethyl azodicarboxylate (1.55 mL, 10 mmol) under N 2 , keeping the internal temperature below 35° C. (exothermic). The solution was stirred for 1.2 h, then diluted with ether, washed with water and brine, dried (MgSO 4 ), filtered and concentrated and the residue (9.5 g, oil) chromatographed 175 g SiO 2 , 15% EtOAc/hexane) giving 1.83 g of a viscous oil.
A solution of 1.73 g of this material and 1.75 g (5.5 mmol) of Bu 4 NF·3H 2 O in 20 mL of methanol was refluxed under N 2 for 2.5 h. The crude product (1.94 g) was isolated with ethyl acetate and chromatographed (100 g SiO 2 , 50% EtOAc/hexane) giving 0.60 g (56%) of a white semisolid. Trituration (4:1 hexane-ether) gave 0.57 g (53%) of a solid.
A stirred solution of 0.40 g of this material in 3 mL of dry pyridine was treated with 0.3 mL of acetic anhydride and stirred overnight at 23° C. under N 2 . The mixture was quenched with 1 mL of methanol, stirred for 15 min, diluted with ether, washed with 1M aqueous HCl, water (until neutral), brine, dried (MgSO4), filtered and concentrated. The residue (0.41 g, oil) was chromatographed (35 g SiO 2 , 33% EtOAc/hexane) to afford 0.33 g (76%) of the title compound as a white foam, m.p. 80°-90° C. (dec).
IR (KBr): 3505, 2927, 2866, 2103 (vs), 1721 (sh 1730), 1268, 1235 cm -1 .
NMR (200 MHz 1 H, CDCl 3 ): δ0.92 (s, 3H, Me-18); 1.21 (s, 3H, Me-19); 1.0-2.1 (m); 2.17 (s, 3H, Ac); 2.25 (s 1H, OH-17); 2.74 (m, 1H, H-8); 3.97 (br s, 1H, H-3); 4.31 (br s, 1H, H-11); 4.94 (AB, J-17, Δν=60, 2H, H-21).
Anal. Calc'd for C 23 H 35 N 3 O 5 : C, 63.72; H, 8.14; N, 9.69. Found: C, 63.39; H, 8.18; N, 9.45.
EXAMPLE 7
Preparation of 3β-Acetamido-21-acetoxy-5β-pregnan-11β, 17α-diol-20-one
A solution of 3β-azido-21-acetoxy-5β-pregnan-11β,17α-one (0.15 g, 0.35 mmol) in 8 mL of absolute ethanol containing 0.03 g of 10% Pd on C was stirred under H 2 (1 atm) at 23° C. for 2 h. The mixture was filtered and concentrated, the residue dissolved in EtOAc, the basic material extracted into 1M aqueous HCl, liberated (Na 2 CO 3 ), extracted (EtOAc) and the organic extract washed with water (until neutral) and brine, dried (MgSO 4 ), filtered and concentrated to provide 58 mg of a solid.
This material was acetylated (1.0 mL of dry pyridine, 0.20 mL of Ac 2 O, 23° C., N 2 , overnight), followed by workup (as described for the steroid of Example 6 [last step]) affording a crude product that was chromatographed (25 g SiO 2 , EtOAc). This product was triturated with ether to afford 51 mg (33%) of product as a white solid, m.p. 179°-181° C.
Ms (CI, isobutane): (M+1)=450 (M + ), 432, 391, 371, 348.
IR (KBr): 3398 (br), 2932, 2865, 1720 (sh. 1740), 1652, 1538, 1375, 1265, 1236 cm -1 .
NMR (200 MHz 1 H, CDCl 3 ): δ0.89, 1.22, 1.99, 2.17 (all s, 3H); 1.0-2.2 (m); 2.7 (t, J=13, 1H, H-8); 3.03 (s, 1H, 0H-17); 4.2 (br s, 1H, H-11); 4.3 (br s, 1H, H-3); 4.96 (AB, J=17.5, Δν=42, 2H, H-21); 5.8 (d, J=10, 1H, NH).
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Angiostatic steroids for use in controlling ocular hypertension are disclosed. Pharmaceutical compositions of the angiostatic steroids and methods for their use in treating ocular hypertension, including controlling the ocular hypertension associated with primary open angle glaucoma, are disclosed. In addition, the combination of the compounds with glucocorticoids for the prevention of elevated IOP during the treatment of inflammation is disclosed.
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